United States
Environmental Protection
k Agency
&EPA!
SOURCE TESTING FINAL REPORT
Fuel Comparison
Coal Only and Carpet
Office of Research and Development
National Homeland Security
Research Center
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SOURCE TESTING FINAL
REPORT
Fuel Comparison - Coal Only
and Carpet Co-Fire
Lehigh Cement Evansville Plant, Fleetwood,
Pennsylvania
Kiln #1 Stack
Volume 1 (Report Text and Appendices 1-3)
November 1-5 and 8-12, 2004
Prepared for:
EPA Office of Research and Development
Prepared by:
ARCADIS G&M
4915 Prospectus Drive, Suite F
Durham, North Carolina 27713
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Table of Contents
Introduction
1.1 Summary of Test Program
1.2 Key Personnel
Plant and Sampling Location Descriptions
2.1 Process Description and Operation
2.2 Control Equipment Description
2.3 Stack Sampling Location
Summary and Discussion of Test Results
3.1 Objectives and Test Matrix
3.2 Presentation of Results
3.2.1 Particulate Results
3.2.2 Metals Emissions Results
3.2.3 HCI, CI", HBr, and Br" Emissions Results
3.2.4 Dioxins and Furans Emissions Results
3.2.5 GEMS Emissions Results
3.3 Field Test Changes and Problems
3.3.1 Variation from Test Methods and/or Planned Activities
Sampling and Analytical Procedures
4.1 Test Methods
4.2 Analytical Methods
Internal QA/QC Activities
5.1 QA/QC Problems
5.2 QA Audits
1
1
3
3
3
3
7
7
11
11
21
21
24
31
34
34
35
35
35
37
37
37
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ARCADIS Table of Contents
List of Tables
Table 1 -1. Key Personnel 2
Table 3-1. Test Matrix 7
Table 3-2: Kiln #1 Particulate, NOX, and SO2 Emissions Summary 12
Table 3-2 continued: Kiln #1 Particulate, NOX, and SO2 Emissions Summary 13
Table 3-2 continued: Kiln #1 Particulate, NOX, and SO2 Emissions Summary 14
Table 3-3. Kiln #1 Stack Filterable PM-io Particulate Emissions Results 15
Table 3-4. Kiln #1 Stack Condensable Particulate Emissions Results 17
Table 3-5. Kiln #1 Stack Total Particulate Emissions Results 18
Table 3-6. Kiln #1 Stack Filterable Particulate Emissions Results 22
Table 3-7. Kiln #1 Stack Metals Emissions Results 23
Table 3-8. Kiln #1 Stack HCI, CI", HBr, and Br" Emissions Results 24
Table 3-9: Dioxins and Furans Emission Data Summary, Kiln No. 1 Exhaust Stack-Coal Only
Testing using EPA M23 25
Table 3-10: Dioxins and Furans Emission Data Summary, Kiln No. 1 Exhaust Stack-Co-fire
Testing using EPA M23 26
Table 3-11. Coal Only Dioxin/Furan Run-by-Run Emission Rates and Concentrations 27
Table 3-12. coal Only Dioxin/Furan Toxic Equivalency Factors 28
Table 3-13. Carpet Co-Fire Dioxin/Furan Run-by-Run Emission Rates and Concentrations 29
Table 3-14. Carpet Co-Fire Dioxin/Furan Toxic Equivalency Factors 30
Table 3-15. Kiln#1 Stack GEMS Results 31
Table 3-16. Preliminary Lehigh GEMS and Production Analyzer Data 33
Table 5-1. QA Audit Samples Results 37
List of Figures
Figure 2-1. Process Schematic 4
Figure 2-2. Kiln #1 Stack Sampling Location 5
Figure 3-1. Particle Size Distribution, Coal Only-Run 1, 10 November 2004 19
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ARCADIS Table of Contents
Figure 3-2. Particle Size Distribution, Coal Only-Run 2, 10 November 2004 19
Figure 3-3. Particle Size Distribution, Coal Only - Run 1, 5 November 2004 20
Figure 3-4. Particle Size Distribution, Coal Only-Run 2, 12 November 2004 20
Figure 3-5. Particle Size Distribution, Coal Only-Run 3, 12 November 2004 20
Appendices
Emissions Results and Example Calculations
Raw Field Data
Process Data
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ARCADIS Table of Contents
IV
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Lehigh Cement
1. Introduction
1.1 Summary of Test Program
The Carpet and Rug Institute (CRI), U.S. Department of Energy (DOE), Georgia Institute of Technology
School of Chemical and Bio-Molecular Engineering, and the US EPA, co-sponsored by Lehigh Cement
Company and the American Society of Mechanical Engineers (ASME), performed a collaborative test
program on the feasibility of using cement kilns for the destruction of post-consumer carpet. Industry wants
to utilize post-consumer carpet as a fuel to replace costly coal. The objective of this project is to conduct a
feasibility test to determine the impact of carpet burning on; kiln fouling, fuel economy, mechanical
equipment operation, and stack emissions.
The source sampling program described here was designed to provide the stack emissions portion of the
data necessary for the feasibility determination. Specifically, the following emissions determinations from
the kiln were required: filterable particulate matter, condensable particulate matter, PMi0 particulate matter,
particle size distribution, HC1, HE", HBr, Br", Resource Conservation and Recovery Act (RCRA) and 1990
Clean Air Act (CAA) metals (Sb, As, Ba, Be, Cd, Cr, Co, Pb, Mn, Hg, Ni, Se, Ag, Ti), dioxin/furans, sulfur
dioxide, nitrogen oxides, and carbon monoxide. In addition, O2 and CO2 concentrations were required for
stack gas molecular weight calculation. ARCADIS G&M was contracted by CRI to provide these data.
Source testing took place on the Kiln #1 Stack at Lehigh Cement's Evansville Plant at 537 Evansville Road
in Fleetwood, Pennsylvania, 19522 on November 1-5 and 8-12, 2004.
1.2 Key Personnel
The key personnel present for all or part of the test program along with their affiliation, role, and contact
information can be seen in Table 1-1.
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Table 1-1. Key Personnel
Name Organization
Peter Smith Lehigh Cement
Charles Bortz Lehigh Cement
Matthew
Realff
Gary
Hinshaw
Dr. Paul
Lemieux
Georgia Tech
ASME
US EPA
Robert Small PA DEP
Gene ARCADIS G &
Stephenson M
Role
Alternative Materials
Specialist
Plant Environmental
Coordinator
Test Burn Project
Manager
Test Observer and Data
Reviewer
Test Coordinator/Work
Assignment Manager
Test Observer
Test Engineer
Phone
(610)
366-4647
(610)
926-1024
(810)
894-1834
(785)
296-5555
(919)
541-0962
(717)
772-2305
(919)
544-4535
E-Mail Address
psmith@lehiqhcement.com
cbortz@lehiqhcement.com
m atthew. realff @ chbe. qatech. edu
qhinshaw@kdhe.state.ks.us
Lemieux.Paul@epamail.epa.gov
robsm al I @ state, pa. us
qstephenson @ arcadis-us.com
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2. Plant and Sampling Location Descriptions
2.1 Process Description and Operation
Lehigh Cement's Evansville Plant operates two identical kilns commissioned in the 1960s. They utilize the
Portland cement manufacturing process. Kiln #1 is 520 feet long and transitions from a 15 foot diameter to
a 17 foot diameter in the taper section (from the 400 to 430 foot mark). It has six tires (and piers) for
support; the drive pier is Pier 4. It can burn a mix of coal, natural gas, and alternative fuels (tires, wood,
carpet) and has a capacity of 1900 short tons per day of clinker. A whole-tire mid-kiln injection system was
installed at the 250 foot mark in the early 1990s. The kiln normally operates at production rate of
approximately 1700 short tons per day. Figure 2-1 is a schematic diagram of Kiln #1. The plant's Title V
permit number is 06-05002.
2.2 Control Equipment Description
The control devices are a cyclone, a spray tower, and a baghouse. The cyclone removes large particulate
matter prior to the spray tower. The spray tower has 16 water injection lances (8 double tips and 8 single
tips). All injection lances have water atomization controls. The baghouse has a total of 2600 bags/cages
split into eight compartments with on-demand pulsing.
2.3 Stack Sampling Location
Emissions sampling was conducted at the stack of Kiln #1. Figure 2-2 is a schematic diagram of the
sampling location showing sampling ports and traverse points.
The kiln stack has four 6-inch sampling ports installed 90 degrees apart at the 228 foot level. The stack has
an inner diameter of 120 inches and has 8 and 10.5 diameters of straight run before and after the test ports
respectively. The minimum of twelve traverse points required by EPA Method 1 were used during the test
runs.
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Lehigh Cement
Evan sville Plant
Portland C em en t M an u factu rln g
Process Schematic
Long-dry Portland Cement Kiln
Figure 2-1. Process Schematic
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Lehigh Cement
Samping
low
185'
BO"
Stack Cross Section
Traverse Points
Point* Distance
SI/4'
111/5'"
is IT
I4W"
KttW
1141,1"
Bit lifel fort
Figure 2-2. Kiln #1 Stack Sampling Location
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Lehigh Cement
3. Summary and Discussion of Test Results
3.1 Objectives and Test Matrix
The purpose of the sampling program was to determine the emissions from the #1 Kiln
Stack of: filterable particulate matter (FP), condensable participate matter (CP), PMi0
particulate matter, particle size distribution (PSD), HC1, Cl", HBr, Br", RCRA and CAA
metals (Sb, As, Ba, Be, Cd, Cr, Co, Pb, Mn, Hg, Ni, Se, Ag), dioxin/furans, sulfur
dioxide, nitrogen oxides, and carbon monoxide. In addition, O2 and CO2 concentrations
were required for stack gas molecular weight calculation. In the QAPP (Quality
Assurance Project Plan - Source Sampling for Post-Consumer Carpet Co-Firing in a
Cement Kiln - ASME/Lehigh Cement), included as Appendix 7, the original intention
was to make the above determinations during each of three conditions; coal only, high
carpet co-fire and low carpet co-fire. After delays on site, it was determined that the
low carpet co-fire condition would be eliminated due to time/funding constraints. The
carpet co-fire rate used during the test program was 2.2 long tons per hour. For
efficiency reasons (the ability to collect both PMi0 and condensable particulate
simultaneously), GARB Method 501/EPA Method 202 were substituted for Modified
EPA Method 201A called for in the QAPP. Table 3-1 presents the test matrix.
Although they are not listed below, EPA Methods 1, 2, and 4 were, as with normal
practice, performed concurrently with EPA Methods 23, 5/26A, and 29.
Table 3-1. Test Matrix
Date Kiln Fuel
Nov 5, 2004
Nov 5, 2004
Nov 5, 2004
Nov 5, 2004
Nov 5, 2004
Nov 5, 2004
Nov 5, 2004
Nov 5, 2004
Nov 5, 2004
Nov 5, 2004
Nov 5, 2004
Nov 5, 2004
Carpet co-fire
Carpet co-fire
Carpet co-fire
Carpet co-fire
Carpet co-fire
Carpet co-fire
Carpet co-fire
Carpet co-fire
Carpet co-fire
Carpet co-fire
Carpet co-fire
Carpet co-fire
Method-Run Number
EPA
EPA
EPA
M23-1
M23-2
M23-3
GARB M501 /EPA M202-HM
EPA
EPA
EPA
EPA
EPA
EPA
EPA
EPA
M3A-1
M6C-1
M7E-1
M10-1
M3A-2
M6C-2
M7E-2
M10-2
Analyte(s)
Dioxins/Furans
Dioxins/Furans
Dioxins/Furans
PM10/PSD/CP
CO2/O2
SO2
NOX
CO
CO2/O2
SO2
NOX
CO
Run Period
09:45-13:35
09:45-13:35
16:20-22:08
16:25-18:25
07:49-12:48
07:49-12:48
07:49-12:48
07:49-12:48
13:09-13:33
13:09-13:33
13:09-13:33
13:09-13:33
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Date
Nov 5, 2004
Nov 5, 2004
Nov 5, 2004
Nov 5, 2004
Nov 8, 2004
Nov 8, 2004
Nov 8, 2004
Nov 8, 2004
Nov 8, 2004
Nov 8, 2004
Nov 8, 2004
Nov 8, 2004
Nov 8, 2004
Nov 8, 2004
Nov 8, 2004
Nov 8, 2004
Nov 8, 2004
Nov 8, 2004
Nov 8, 2004
Nov 8, 2004
Nov 8, 2004
Nov 8, 2004
Nov 8, 2004
Nov 8, 2004
Nov 8, 2004
Nov 8, 2004
Nov 9, 2004
Nov 9, 2004
Nov 9, 2004
Nov 9, 2004
Nov 9, 2004
Nov 9, 2004
Kiln Fuel
Carpet co-fire
Carpet co-fire
Carpet co-fire
Carpet co-fire
Carpet co-fire
Carpet co-fire
Carpet co-fire
Carpet co-fire
Carpet co-fire
Carpet co-fire
Carpet co-fire
Carpet co-fire
Carpet co-fire
Carpet co-fire
Carpet co-fire
Carpet co-fire
Carpet co-fire
Carpet co-fire
Carpet co-fire
Carpet co-fire
Carpet co-fire
Carpet co-fire
Carpet co-fire
Carpet co-fire
Carpet co-fire
Carpet co-fire
Coal Only
Coal Only
Coal Only
Coal Only
Coal Only
Coal Only
Method-Run Number
EPA M3A-3
EPA M6C-3
EPA M7E-3
EPA M1 0-3
EPA M5/26A-1
EPA M5/26A-2
EPA M5/26A-3*
EPA M29-1
EPA M29-2
EPA M29-3*
EPA M3A-1
EPA M6C-1
EPA M7E-1
EPAM10-1
EPA M3A-2
EPA M6C-2
EPA M7E-2
EPA M1 0-2
EPA M3A-3
EPA M6C-3
EPA M7E-3
EPA M1 0-3
EPA M3A-4
EPA M6C-4
EPA M7E-4
EPA M1 0-4
EPA M23-4
EPA M23-5
EPA M23-6A**
EPA M3A-1
EPA M6C-1
EPA M7E-1
Analyte(s)
CO2/O2
SO2
NOx
CO
FP/HCI/HF7HBr/Br"
FP/HCI/HF7HBr/Br"
FP/HCI/HF7HBr/Br"
RCRA/CAA Metals
RCRA/CAA Metals
RCRA/CAA Metals
CO2/O2
SO2
NOX
CO
CO2/O2
SO2
NOX
CO
CO2/O2
SO2
NOX
CO
CO2/O2
SO2
NOX
CO
Dioxins/Furans
Dioxins/Furans
Dioxins/Furans
CO2/O2
SO2
NOX
Run Period
15:34-20:05
15:34-20:05
15:34-20:05
15:34-20:05
08:50-11:14
12:35-15:02
16:40-18:40
08:50-11:14
12:35-15:03
16:40-18:40
08:18-10:10
08:18-10:10
08:18-10:10
08:18-10:10
12:36-15:03
12:36-15:03
12:36-15:03
12:36-15:03
16:41-18:07
16:41-18:07
16:41-18:07
16:41-18:07
18:27-18:41
18:27-18:41
18:27-18:41
18:27-18:41
07:50-11:18
07:50-11:18
12:45-13:45
07:02-11:17
07:02-11:17
07:02-11:17
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Lehigh Cement
Date
Nov 9, 2004
Nov 9, 2004
Nov 9, 2004
Nov 9, 2004
Nov 9, 2004
Nov 10, 2004
Nov 10, 2004
Nov 10, 2004
Nov 10, 2004
Nov 10, 2004
Nov 10, 2004
Nov 10, 2004
Nov 10, 2004
Nov 10, 2004
Nov 10, 2004
Nov 10, 2004
Nov 10, 2004
Nov 10, 2004
Nov 10, 2004
Nov 10, 2004
Nov 1 1 , 2004
Nov 1 1 , 2004
Nov 1 1 , 2004
Nov 1 1 , 2004
Nov 1 1 , 2004
Nov 1 1 , 2004
Nov 1 1 , 2004
Nov 1 1 , 2004
Nov 1 1 , 2004
Nov 1 1 , 2004
Nov 1 1 , 2004
Kiln Fuel
Coal Only
Coal Only
Coal Only
Coal Only
Coal Only
Coal Only
Coal Only
Coal Only
Coal Only
Coal Only
Coal Only
Coal Only
Coal Only
Coal Only
Coal Only
Coal Only
Coal Only
Coal Only
Coal Only
Coal Only
Coal Only
Coal Only
Coal Only
Coal Only
Coal Only
Coal Only
Coal Only
Coal Only
Coal Only
Coal Only
Coal Only
Method-Run Number
EPAM10-1
EPA M3A-2
EPA M6C-2
EPA M7E-2
EPA M1 0-2
EPA M23-6
GARB M501 /EPA M202-
Basel
GARB M501 /EPA M202-
Base2
EPA M3A-1
EPA M6C-1
EPA M7E-1
EPA M1 0-1
EPA M3A-2
EPA M6C-2
EPA M7E-2
EPA M 10-2
EPA M3A-3
EPA M6C-3
EPA M7E-3
EPA M 10-3
EPA M5/26A-4
EPA M5/26A-5
EPA M5/26A-6
EPA M29-4
EPA M29-5
EPA M29-6
EPA M3A-1
EPA M6C-1
EPA M7E-1
EPA M1 0-1
EPA M3A-2
Analyte(s)
CO
CO2/O2
SO2
NOx
CO
Dioxins/Furans
PMio/PSD/CP
PMio/PSD/CP
CO2/O2
SO2
NOX
CO
CO2/O2
SO2
NOX
CO
CO2/O2
SO2
NOX
CO
FP/HCI/HF7HBr/Br"
FP/HCI/HF7HBr/Bf
FP/HCI/HF7HBr/Bf
RCRA/CAA Metals
RCRA/CAA Metals
RCRA/CAA Metals
CO2/O2
SO2
NOX
CO
CO2/O2
Run Period
07:02-11:17
12:46-13:54
12:46-13:54
12:46-13:54
12:46-13:54
11:50-15:50
11:30-17:55
11:15-17:40
07:16-10:19
07:16-10:19
07:16-10:19
07:16-10:19
11:51-13:50
11:51-13:50
11:51-13:50
11:51-13:50
15:22-16:53
15:22-16:53
15:22-16:53
15:22-16:53
08:10-10:35
11:40-14:02
15:00-17:25
08:10-10:35
11:40-14:02
15:00-17:25
07:56-09:55
07:56-09:55
07:56-09:55
07:56-09:55
10:19-12:18
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Date
Kiln Fuel
Method-Run Number
Analyte(s)
Run Period
Nov 1 1 , 2004 Coal Only
Nov 1 1 , 2004 Coal Only
Nov 1 1 , 2004 Coal Only
Nov 1 1 , 2004 Coal Only
Nov 1 1 , 2004 Coal Only
Nov 1 1 , 2004 Coal Only
Nov 1 1 , 2004 Coal Only
Nov 1 1 , 2004 Coal Only
Nov 1 1 , 2004 Coal Only
Nov 1 1 , 2004 Coal Only
Nov 1 1 , 2004 Coal Only
Nov 12, 2004 Carpet co-fire
Nov 12, 2004 Carpet co-fire
Nov 12, 2004 Carpet co-fire
Nov 12, 2004 Carpet co-fire
Nov 12, 2004 Carpet co-fire
Nov 12, 2004 Carpet co-fire
Nov 12, 2004 Carpet co-fire
Nov 12, 2004 Carpet co-fire
Nov 12, 2004 Carpet co-fire
Nov 12, 2004 Carpet co-fire
Nov 12, 2004 Carpet co-fire
Nov 12, 2004 Carpet co-fire
Nov 12, 2004 Carpet co-fire
Nov 12, 2004 Carpet co-fire
Nov 12, 2004 Carpet co-fire
Nov 12, 2004 Carpet co-fire
Nov 12, 2004 Carpet co-fire
Nov 12, 2004 Carpet co-fire
EPA M6C-2
EPA M7E-2
EPA M 10-2
EPA M3A-3
EPA M6C-3
EPA M7E-3
EPA M 10-3
EPA M3A-4
EPA M6C-4
EPA M7E-4
EPA M 10-4
GARB M501 /EPA M202-HI2
GARB M501 /EPA M202-HI3
EPA M3A-1
EPA M6C-1
EPA M7E-1
EPA M1 0-1
EPA M3A-2
EPA M6C-2
EPA M7E-2
EPA M 10-2
EPA M3A-3
EPA M6C-3
EPA M7E-3
EPA M 10-3
EPA M3A-4
EPA M6C-4
EPA M7E-4
EPA M 10-4
SO2
NOX
CO
CO2/O2
SO2
NOX
CO
CO2/O2
SO2
NOX
CO
PM10/PSD/CP
PM10/PSD/CP
CO2/O2
SO2
NOX
CO
CO2/O2
SO2
NOX
CO
CO2/O2
SO2
NOX
CO
CO2/O2
SO2
NOX
CO
10:19-12:18
10:19-12:18
10:19-12:18
12:41-14:17
12:41-14:17
12:41-14:17
12:41-14:17
15:01-17:00
15:01-17:00
15:01-17:00
15:01-17:00
10:20-18:35
10:20-18:35
10:46-12:45
10:46-12:45
10:46-12:45
10:46-12:45
13:04-15:03
13:04-15:03
13:04-15:03
13:04-15:03
15:21-17:20
15:21-17:20
15:21-17:20
15:21-17:20
17:38-18:37
17:38-18:37
17:38-18:37
17:38-18:37
*Run shortened to ~65 minutes due to process upset - run was not repeated and was analyzed
and reported
**Run shortened to ~55 minutes due to process upset - run was aborted , not analyzed, and
repeated on 10 Nov
10
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3.2 Presentation of Results
Table 3-2 presents a summary of particulate, NOX, and SO2 emissions results from the
test program along with process data. See individual test method results in subsequent
subsections. Detailed results can be seen in Appendix 1.
3.2.1 Particulate Results
Particulate emission quantifications were accomplished in three different ways: GARB
Method 501 was utilized for PMi0 and particle size distribution; EPA Method 202
(incorporated as the back half of the GARB Method 501 runs) was used to quantify
condensable particulates; and EPA Method 5 (as the front half of EPA Method 26A
runs) made filterable particulate determinations. Due to port restrictions and different
sampling times, the Method 501/202 testing did not take place simultaneously with the
Method 5/26A testing. For this reason they are reported separately below.
3.2.1.1
Filterable PMio Particulate Emissions Results
Table 3-3 presents filterable PMio particulate results. Filterable PMio particulate mass
for each run was derived from the sum of the sampling nozzle, PMio cyclone and the
Andersen impactor media (including back-up filter). The nozzle and cyclone catch was
zero in each case, suggesting that filterable PMio particulate and filterable particulate
are functionally the same. As a cautionary note, the Andersen impactor stage catch
weights were extremely low even though sampling runs were 2-8 hours long. This has
implications for the particle size determinations to be discussed in detail in a later
section but, for the purposes of filterable PMio particulate determination, the main point
is that the weights are likely to be somewhat imprecise. The results below therefore are
probably useful for comparison purposes only.
11
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Table 3-2: Kiln #1 Particulate, NOx, and SO2 Emissions Summary
Test Date
Test Run Number
Filterable
Particulate, NOx,
and SO2
Sampling/Stack
Summary Data
Filterable
Particulate
Recovery Summary
Data
NOx Emissions
Summary
SO2 Emissions
Summary
Run Description (Supplemental process summary
data are listed below)
Test Duration, (minutes)
Clinker Production Rate, (tons/hr)
Baghouse Inlet Temperature, (°F)
Chain Gas Temperature, (°F)
Coal (tons/hr)
Kiln Amps, (amps)
Oxygen, (%)
Carbon Dioxide, (%)
Stack Gas Temperature, (UF)
Stack Gas Moisture, (%)
Volumetric Flowrate, (dscfm)
Amount of Acetone Used to Rinse FH Sample Train, (ml)
Amount of H20 Used to Rinse BH Sample Train, (ml) -
Inorganic Fraction
Amount of MeCI2 Used to Rinse BH Sample Train, (ml) -
Organic Fraction
Filterable Particulate Weight, (mg)
Filterable Particulate Weight < 10 |jm, (mg)
Organic Condensable Particulate Weight, (mg)
Inorganic Condensable Particulate Weight, (mg)
Total Particulate Weight, (mg)
Required Sample Volume, (dscf)
Allowable Emission Concentration*, (gr/dscf)
Emission Rate, (Ib/hr)
Allowable Emission Rate, (Ib/hr)
Emission Rate, (Ib/ton of Clinker)
Isokinetic Ratio, (%)
NOx Emission Concentration, (ppmvd)
NOx Emission Rate, (Ib/hr)
NOx Emission Rate, (Ib/ton of Clinker)
Allowable NOx Emission Rate, (Ib/ton of Clinker)
Allowable SO2 Emission Concentration**, (ppmvd)
SO2 Emission Rate, (Ib/ton of Clinker)
11/9/2OO4 11/9/2OO4 11/1O/2OO4 11/1O/2OO4 11/1O/2OO4 11/11/2OO4 11/11/2OO4 11/11/2OO4
124 Average 1 2 Average 123 Average
Filterable PM Filterable PM Filterable PM Filterable
Dioxin/ Dioxin/ Dioxin/ PM1O CARB PM1O CARB and and and PM and
M 23-4 Coal
Only
208
75.6
407
1490
11.3
23.4
4.9
26.5
396
18.7
100
NA
150
NA
NA
NA
NA
NA
144
0.02
NA
13.3
NA
96.8
889
344.6
4.56
8.83
1.5
500
1.54E-02
M 23- 5 Coal
Only
208
75.6
407
1490
11.3
23.4
4.9
26.5
396
20.5
100
NA
150
NA
NA
NA
NA
NA
144
0.02
NA
13.0
NA
96.8
556.9
7.36
8.83
23.6
500
2.37E-01
E RAM 23-6
Coal Only
205
72.3
401
1484
10.6
21.7
5.3
26.3
393
18.6
100
NA
150
NA
NA
NA
NA
NA
144
0.02
NA
13.3
NA
95.7
452.8
6.26
8.83
34.0
500
3.63E-01
Furan Coal
Only M23
74.5
405
1488
11.0
22.8
5.0
26.4
395
19.3
100
NA
150
NA
NA
NA
NA
NA
144
0.02
NA
13.2
NA
96.4
452.3
6.07
8.83
19.7
500
2.03E-01
M2O2- Basel
Coal Only
385
70.1
402
1487
10.3
21.9
5.0
26.3
391
20.2
150
N/A
N/A
NA
1.8
0.7
476.6
479.1
N/A
0.02
0.2
11.7
2.77E-03
96.5
800
272.7
3.89
8.83
-3.0
500
-2.92E-02
M2O2-Base2
Coal Only
385
70.2
402
1486
10.3
21.9
5.0
26.3
394
18.8
150
NA
NA
NA
5.9
0.8
600.1
606.8
NA
0.02
0.6
12.7
9.22E-03
96.6
809
297.6
4.24
8.83
44.0
500
4.61E-01
Only
M5O1/2O2
70.2
402
1487
10.3
21.9
5.0
26.3
393
19.5
150
NA
NA
NA
3.9
0.8
538.4
543.0
NA
0.02
0.4
12.2
5.99E-03
96.6
805
285.1
4.06
8.83
20.5
500
2.07E-01
EPA M5/26A
4 Coal Only
145
76.7
406
1467
10.6
21.6
4.9
26.7
395
20.3
150
N/A
N/A
11.5
NA
NA
NA
NA
50
0.02
1.1
12.8
1.45E-02
90.1
900
334.2
4.36
8.83
5.8
500
5.63E-02
EPA M 5/26 A
5 Coal Only
142
69.2
400
1505
10.7
21.9
4.2
25.3
394
20.2
150
N/A
N/A
7.3
NA
NA
NA
NA
50
0.02
0.7
13.1
9.86E-03
93.0
766
290.4
4.19
8.83
30.0
500
3.29E-01
EPA M 5/26 A
6 Coal Only
147
75.1
403
1476
10.6
21.0
4.9
26.9
396
19.6
150
N/A
N/A
1.0
NA
NA
NA
NA
50
0.02
0.1
13.2
1.25E-03
93.1
906
346.8
4.62
8.83
15.0
500
1.53E-01
Coal Only
M5/26A
73.7
403
1483
10.6
21.5
4.7
26.3
395
20.0
150
NA
NA
6.6
NA
NA
NA
NA
50
0.02
0.6
13.0
8.54E-03
92.1
857
323.8
4.40
8.83
16.9
500
1.74E-01
12
-------
Ot*
Source Testing Final
Report
Lehigh Cement
Table 3-2 continued: Kiln #1 Particulate, NOX, and SO2 Emissions Summary
11/11/2OO4
1
Metals EPA
M29-4 Coal
Only
8: 10-10:35
145
76.7
118.8
406
1467
10.6
21.6
4.9
26.7
396
19.9
74,121
100
N/A
N/A
NA
NA
NA
NA
NA
111.1
72
NA
0.02
NA
12.7
NA
95.5
90-110
900
332.2
4.33
8.83
5.3
500
4.29
5.60E-02
11/11/2OO4
2
Metals EPA
M29-5 Coal
Only
11:40-14:02
142
69.2
107.3
400
1505
10.7
21.9
4.2
25.3
395
19.6
78,500
100
N/A
N/A
NA
NA
NA
NA
NA
123.4
72
NA
0.02
NA
13.5
NA
98. 5
90-110
766
299.3
4.32
8.83
30.0
500
23.48
3.39E-01
11/11/2OO4
3
Metals EPA
M29-6 Coal
Only
15:00-17:25
145
75.0
116.2
403
1476
10.6
21.0
4.9
26.9
398
19.7
76,832
100
N/A
N/A
NA
NA
NA
NA
NA
117.9
72
NA
0.02
NA
13.2
NA
97.8
90-110
906
346.5
4.62
8.83
15.0
500
11.50
1.53E-01
Average
Metals Coal
Only M29
73.6
114.1
403
1483
10.6
21.5
4.7
26.3
396
19.7
76,484
100
NA
NA
NA
NA
NA
NA
NA
117.5
72
NA
0.02
NA
13.1
NA
97.3
90-110
857
326.5
4.43
8.83
16.9
500
12.92
1.75E-01
11/5/2OO4
1
Dioxin/
Furan
EPAM23-1
Carpet
Cofire
9:45-13:35
230
71.0
110.1
409
1533
9.4
23.2
5.0
26.2
400
19.8
66,034
100
NA
150
NA
NA
NA
NA
NA
198.8
144
NA
0.02
NA
11.3
NA
91.5
90-110
866
284.9
4.01
8.83
398.2
500
262.14
3.69E + 00
11/5/2OO4
2
Dioxin/
Furan
EPAM23-2
Carpet
Cofire
9:45-13:35
230
71.0
110.1
409
1533
9.4
23.2
5.0
26.2
401
20.1
58,003
100
NA
150
NA
NA
NA
NA
NA
199.6
144
NA
0.02
NA
9.9
NA
102.2
90-110
436
125.8
1.77
8.83
305.6
500
176.71
2.49E + 00
11/5/2OO4
3
Dioxin/
Furan
EPAM23-3
Carpet
Cofire
16:20-22:08
348
73.0
113.2
409
1526
9.5
22.0
4.9
26.5
402
20.6
72,494
100
NA
150
NA
NA
NA
NA
NA
173.7
144
NA
0.02
NA
12.4
NA
105.2
90-110
585
211.2
2.89
8.83
320.5
500
231.63
3.17E + 00
Average
Dioxin/
Furan
Carpet
CoFire M23
71.7
111.1
409
1530
9.4
22.8
5.0
26.3
401
20.2
65,510
100
NA
150
NA
NA
NA
NA
NA
190.7
144
NA
0.02
NA
11.2
NA
99.6
90-110
629
205.2
2.86
8.83
341.4
500
222.99
3.11E+00
11/5/2OO4
1
PM1O CARB
M5O1/EPA
M202-HI1
Carpet
Cofire
16:25-18:25
120
73.3
113.6
409
1537
9.5
21.8
4.9
26.5
400
20.9
59,995
150
N/A
N/A
NA
1.9
1.5
138.4
141.8
34.7
NA
S.40E-04
0.02
0.4
10.3
5.92E-03
99.0
90-110
585
174.8
2.38
8.83
320.5
500
191.69
2.61E + 00
11/12/2OO4
2
PM1O CARB
M501/EPA
M202-HI2
Carpet Cofire
10:20-18:35
495
73.0
113.1
411
1484
9.4
21.4
5.1
26.4
397
21.0
72,600
150
N/A
N/A
NA
5.4
0.6
188.4
194.4
130.0
NA
6.40E-04
0.02
0.4
12.4
5.47E-03
105.2
90-110
585
211.5
2.90
8.83
320.5
500
231.97
3.1SE + 00
11/12/2OO4
3
PM1O CARB
M501/EPA
M202-HI3
Carpet Cofire
10:20-18:35
495
73.0
113.1
411
1484
9.4
21.4
5.1
26.4
396
20.8
70,114
150
N/A
N/A
NA
4.5
0.5
319.5
324.5
138.7
NA
5.00E-04
0.02
0.3
12.0
4.12E-03
109.4
90-110
585
204.2
2.80
8.83
320.5
500
224.02
3.07E + 00
Average
PM1O
Carpet
Cofire
M501/202
73.1
113.3
411
1502
9.4
21.5
5.0
26.4
398
20.9
67,570
150
N/A
N/A
NA
3.9
0.9
215.4
220.2
101.2
NA
6.60E-04
0.02
0.4
11.6
5.17E-03
90-110
585
196.8
2.69
8.83
320.5
500
215.89
2.95E + 00
13
-------
Ot*
Source Testing Final
Report
Lehigh Cement
Table 3-2 continued: Kiln #1 Particulate, NOX, and SO2 Emissions Summary
11/8/2OO4
1
Filterable
PM and
Halogens
EPA
M5/26A-1
Carpet
Cofire
8:50-11:14
144
75.4
116.9
405
1470
9.6
24.1
5.3
25.7
404
19.0
80,885
150
N/A
N/A
6.9
NA
NA
NA
NA
116.3
50
9.15E-04
0.02
0.6
13.9
8.42E-03
94.7
90-110
990
398.7
5.29
8.83
22.8
500
18.39
2.44E-01
11/8/2OO4
2
Filterable
PM and
Halogens
EPA
M5/26A-2
Carpet
Cofire
12:35-15:02
147
72.8
112.9
401
1497
9.7
22.6
5,0
26.2
404
19.3
79,881
150
N/A
N/A
6.6
NA
NA
NA
NA
114.8
50
8.87E-04
0.02
0.6
13.7
8.35E-03
94.6
90-110
732
291.4
4.00
8.83
71.5
500
56.94
7.82E-01
11/8/2OO4
3
Filterable
PM and
Halogens
EPA
M5/26A-3
Carpet
Cofire
16:40-18:40
120
72.2
111.9
415
1524
9.7
22.8
5.5
26.1
405
19.2
81,659
150
N/A
N/A
9.3
NA
NA
NA
NA
64.7
50
2.22E-03
0.02
1.6
14.0
2.15E-02
96.3
90-110
929
377.8
5.24
8.83
32.1
500
26.16
3.63E-01
Average
Filterable
PM and
Halogens
Carpet
Cofire
M5/26A
-
73.5
113.9
407
1497
9.7
23.2
5.4
26.0
404
19.2
80,808
150
NA
NA
7.6
NA
NA
NA
NA
98.6
50
1.34E-03
0.02
0.9
13.9
1.28E-02
95.2
90-110
884
355.7
4.84
8.83
42.1
500
33.95
4.62E-01
11/8/2OO4
1
Metals EPA
M29-1
Carpet
Cofire
8:50-11:14
144
75.4
116.9
405
1470
9.6
24.1
5.3
25.7
406
19.7
77,408
100
N/A
N/A
NA
NA
NA
NA
NA
120.7
72
NA
0.02
NA
13.3
NA
99.4
90-110
990
381.6
5.06
8.83
22.8
500
17.59
2.33E-01
11/8/2OO4
2
Metals EPA
M29-2
Carpet
Cofire
12:35-15:03
148
72.8
112.9
401
1497
9.7
22.6
5.0
26.2
404
20.0
78,744
100
N/A
N/A
NA
NA
NA
NA
NA
122.2
72
NA
0.02
NA
13.5
NA
98.9
90-110
732
287.2
3.94
8.83
71.5
500
56.13
7.71E-01
11/8/2OO4
3
Metals EPA
M29-3
Carpet
Cofire
16:40-18:40
120
72.2
111.9
415
1524
9.7
22.8
5.5
26.1
404
20.9
75,050
100
N/A
N/A
NA
NA
NA
NA
NA
59.4
72
NA
0.02
NA
12.9
NA
93.2
90-110
929
347.3
4.81
8.83
32.1
500
24.05
3.33E-01
Average
Metals
Carpet
Cofire M29
-
73.5
113.9
407
1497
9.7
23.2
5.3
26.0
405
20.2
77,067
100
NA
NA
NA
NA
NA
NA
NA
100.8
72
NA
0.02
NA
13.2
NA
97.2
90-110
884
339.2
4.62
8.83
42.1
500
32.38
4.41E-01
14
-------
Source Testing Final
Report
Lehigh Cement
Table 3-3. Kiln #1 Stack Filterable PMio Particulate Emissions Results
Run 1 Coal Only- Nov 10, 2004,11:30-17:55
Concentration (gr/dscf) 3.31 x 10"4
Concentration (mg/dscm) 0.76
Emissions, Ib/hr 0.19
Run 2 Coal Only - Nov 10, 2004,11:15-17:40
Concentration (gr/dscf) 1.02 x 10"3
Concentration (mg/dscm) 2.34
Emissions, Ib/hr 0.65
Average Coal Only
Concentration (gr/dscf) 6.77 x 10"4
Concentration (mg/dscm) 1.55
Emissions, Ib/hr 0.42
Run 1 Carpet Co-Fire - Nov 5, 2004,16:25-18:25
Concentration (gr/dscf) 8.44 x 10"4
Concentration (mg/dscm) 1.93
Emissions, Ib/hr 0.43
Run 2 Carpet Co-Fire - Nov 12, 2004,10:20-18:35
Concentration (gr/dscf) 6.41 x10"4
Concentration (mg/dscm) 1.47
Emissions, Ib/hr 0.40
Run 3 Carpet Co-Fire - Nov 12, 2004,10:20-18:35
Concentration (gr/dscf) 5.00 x 10"4
Concentration (mg/dscm) 1.15
Emissions, Ib/hr 0.30
Average Carpet Co-Fire
Concentration (gr/dscf) 6.62 x 10"4
Concentration (mg/dscm) 1.51
Emissions, Ib/hr 0.38
15
-------
Source Testing Final
Report
Lehigh Cement
3.2.12
Condensable Particulate Emissions Results
Condensable participate emissions results can be seen in Table 3-4. The samples were
collected by EPA Method 202 installed as the back half of the GARB Method 501
PMio participate runs reported above. Condensable particulate emissions were further
divided into organic and inorganic fractions by the EPA Method 202 laboratory
analysis procedures.
3.2.13
Total Particulate Emissions Results
Total particulate emissions results can be seen in Table 3-5. Total particulate is
calculated by summing the particulate from all fractions of the GARB Method 501 and
adding it to the sum of the organic and inorganic fractions of the EPA Method 202.
3.2.14
Particle Size Distribution Results
Particle size distribution determinations were made by an analysis of the Andersen
impactor data for each GARB Method 501 run. There is uncertainty associated with the
results due to the fact that the individual impactor stage particulate catches were very
light compared with the stage catch weights recommended by the impactor
manufacturer for a successful particle size distribution determination. It is
recommended that each stage collect a mass of 2-10 milligrams. Most stages collected
a mass much less than that and some collected less than was found on the blank
impactor media. For this reason, the data must be considered to be of limited
usefulness. It is believed that the fact that no particulate was caught on either the
sampling nozzles or the PMio cyclones is a good indication that no particulate matter
greater than 10 j^tm in aerodynamic diameter escapes the baghouse.
Particle size distribution results can be usefully presented graphically as a plot of mean
particle size diameter vs. the log of the calculated number of particles (assuming a
particle density of one gram per cubic centimeter) on each stage. These plots are
presented in Figures 3-1 through 3-5 below. The sampling dates and times in these
figures are the sames as for Tables 3-3 through 3-5. The lines connecting points on the
graphs are meant merely to focus the eye and not to necessarily imply any actual
properties of the data.
16
-------
ARCADE
Source Testing Final
Report
Lehigh Cement
Table 3-4. Kiln #1 Stack Condensable Particulate Emissions Results
Run 1 Coal Only - Nov 10,
2004,11:30-17:55
Concentration (gr/dscf)
Concentration (mg/dscm)
Emissions, Ib/hr
Run 2 Coal Only - Nov 10,
2004,11:15-17:40
Concentration (gr/dscf)
Concentration (mg/dscm)
Emissions, Ib/hr
Average Coal Only
Concentration (gr/dscf)
Concentration (mg/dscm)
Emissions, Ib/hr
Run 1 Carpet Co-Fire -
Nov 5, 2004, 16:25-18:25
Concentration (gr/dscf)
Concentration (mg/dscm)
Emissions, Ib/hr
Run 2 Carpet Co-Fire -
Nov 12, 2004, 10:20-18:35
Concentration (gr/dscf)
Concentration (mg/dscm)
Emissions, Ib/hr
Run 3 Carpet Co-Fire -
Nov 12, 2004, 10:20-18:35
Concentration (gr/dscf)
Concentration (mg/dscm)
Emissions, Ib/hr
Average Carpet Co-Fire
Concentration (gr/dscf)
Concentration (mg/dscm)
Emissions, Ib/hr
Organic
1.29x10"4
0.294
0.0755
Organic
1.39x10"4
0.317
0.0878
Organic
1.34x10'4
0.306
0.0817
Organic
6.66 x10"4
1.52
0.3427
Organic
7.12 x10"5
0.16
0.0443
Organic
5.56 x10"5
0.13
0.0334
Organic
2.64 x10'4
0.60
0.1401
Inorganic
8.76 x10"2
200.5
51.4
Inorganic
1.04x10"1
238.0
65.9
Inorganic
9.59 x10'2
219.2
58.6
Inorganic
6.15 x10"2
140.7
31.6
Inorganic
2.24 x10"2
51.2
13.9
Inorganic
3.55 x10"2
81.3
21.4
Inorganic
3.98 x10'2
91.9
22.3
17
-------
Source Testing Final
Report
Lehigh Cement
Table 3-5. Kiln #1 Stack Total Participate Emissions Results
Run 1 Coal Only- Nov 10, 2004,11:30-17:55
Concentration (gr/dscf)
Concentration (mg/dscm)
Emissions, Ib/hr
8.81 x1(T
201.5
51.7
Run 2 Coal Only - Nov 10, 2004,11:15-17:40
Concentration (gr/dscf)
Concentration (mg/dscm)
Emissions, Ib/hr
1.05x10"1
240.6
66.6
Average Coal Only
Concentration (gr/dscf)
Concentration (mg/dscm)
Emissions, Ib/hr
9.66x10"
221.1
59.1
Run 1 Carpet Co-Fire - Nov 5, 2004,16:25-18:25
Concentration (gr/dscf)
Concentration (mg/dscm)
Emissions, Ib/hr
6.30x10"^
144.1
32.4
Run 2 Carpet Co-Fire - Nov 12, 2004,10:20-18:35
Concentration (gr/dscf)
Concentration (mg/dscm)
Emissions, Ib/hr
2.31 x1
52.8
14.4
Run 3 Carpet Co-Fire - Nov 12, 2004,10:20-18:35
Concentration (gr/dscf)
Concentration (mg/dscm)
Emissions, Ib/hr
3.61 x10~'
82.6
21.7
Average Carpet Co-Fire
Concentration (gr/dscf)
Concentration (mg/dscm)
Emissions, Ib/hr
4.07x10"
93.2
22.8
18
-------
Source Testing Final
Report
Lehigh Cement
JD 2.50E+09 :,
| -ft 2.00E+09
So 1.50E+09 \
Q.
Q
£ 1-
^ "5 5.00E+08
O.OOE+00
0.100 1.000 10.000
Particle Aerodiameter (um)
100.000
Figure 3-1. Particle Size Distribution, Coal Only - Run 1,10 November 2004
^ '5T Q OOF+1 1 :
So :
Q. '•? ? noF+1 1 :
O ro :
0) Q.
0^1 nnF+l 1 :
"D
2 n nnp_i_nn "
\
\
>»^.
0.100 1.000 10.000 100.
Particle Aerodiameter (um)
Figure 3-2. Particle Size Distribution, Coal Only - Run 2,10 November 2004
19
-------
IS
Source Testing Final
Report
Lehigh Cement
S w -i nnF-i-1 1 "
Q. ?
Q m R nnF-i-in "
£ :
^ n nnp-i_nn
\ I
\
0.100 1.000 10.C
Particle Aerodia meter (um)
Figure 3-3. Particle Size Distribution, Coal Only - Run 1, 5 November 2004
dN/dlogDp (number of
particles)
3
3
2
2
1
1
5
0
50E+11 -
nnF-i-11 :
^DF-i-11 :
OOE+11 :
50E+1 1
OOE+1 1
OOE+10
OOE+00
A
/ \
/ \
/ \
/ \
^— ~^^
0.100 1.000 10.(
Particle Aerodia meter (um)
Figure 3-4. Particle Size Distribution, Coal Only - Run 2,12 November 2004
& :
E ^
E w •< ROF+1 1 :
£• ~o '-
n '^ 1 nnF-i-1 1 -
O co :
O) Q.
n _ R OOF+10 :
1 ° ;
2 O.OOE+00 :
0.1
»
A
/ \
\
00 1.000 10.000
Particle Aerodiameter (um)
Figure 3-5. Particle Size Distribution, Coal Only - Run 3,12 November 2004
20
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Source Testing Final
Report
Lehigh Cement
3.2.1.5 Filterable Particulate Emissions Results
Filterable participate determinations were made by the use of EPA Method 5 installed
as the front half of an EPA Method 26A sampling train. These results are presented in
Table 3-6.
3.2.2 Metals Emissions Results
Metals emissions were determined by EPA Method 29. Results are presented in Table
3-7.
3.2.3 HCI, CI", HBr, and Br" Emissions Results
HC1, Cl", HBr, and Br" emissions results, as determined by EPA Method 26A, are
presented in Table 3-8.
21
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Source Testing Final
Report
Lehigh Cement
Table 3-6. Kiln #1 Stack Filterable Participate Emissions Results
Run 1 Coal Only- Nov 11, 2004, 08:10-10:35
Concentration (gr/dscf) 1.74 x 10"3
Concentration (mg/dscm) 3.98
Emissions, Ib/hr 1.11
Run 2 Coal Only - Nov 11, 2004,11:40-14:02
Concentration (gr/dscf) 1.05 x 10"3
Concentration (mg/dscm) 2.39
Emissions, Ib/hr 0.68
Run 3 Coal Only- Nov 11, 2004,15:00-17:25
Concentration (gr/dscf) 1.42 x 10"4
Concentration (mg/dscm) 0.32
Emissions, Ib/hr 0.094
Average Coal Only
Concentration (gr/dscf) 9.76 x 10~4
Concentration (mg/dscm) 2.23
Emissions, Ib/hr 0.63
Run 1 Carpet Co-Fire - Nov 8, 2004, 08:50-11:14
Concentration (gr/dscf) 9.15 x 10"4
Concentration (mg/dscm) 2.09
Emissions, Ib/hr 0.64
Run 2 Carpet Co-Fire - Nov 8, 2004,12:35-15:02
Concentration (gr/dscf) 8.87 x 10"4
Concentration (mg/dscm) 2.03
Emissions, Ib/hr 0.61
Run 3 Carpet Co-Fire - Nov 8, 2004,16:40-18:40
Concentration (gr/dscf) 2.22 x 10"3
Concentration (mg/dscm) 5.07
Emissions, Ib/hr 1.55
Average Carpet Co-Fire
Concentration (gr/dscf) 1.34 x 10"3
Concentration (mg/dscm) 3.07
Emissions, Ib/hr 0.93
22
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ARCADIS
Source Testing Final
Report
Lehigh Cement
Table 3-7. Kiln #1 Stack Metals Emissions Results
Emission Rate, mg/dscm
Metal
Antimony
Arsenic
Barium
Beryllium
Cadmium
Chromium
Cobalt
Lead
Manganese
Mercury
Nickel
Selenium
Silver
Thallium
Antimony
Arsenic
Barium
Beryllium
Cadmium
Chromium
Cobalt
Lead
Manganese
Mercury
Nickel
Selenium
Silver
Thallium
Run 1, Coal
Only- Nov11,
2004, 08:10-
10:35
0.0000
0.0000
0.0000
0.0000
0.0003
0.0016
0.0000
0.0016
0.0023
0.0178
0.0014
0.0138
0.0000
0.0249
0.0000
0.0000
0.0000
0.00001
0.00036
0.0031
0.0000
0.0012
0.0597
0.0204
0.0019
0.0154
0.0000
0.0166
Run 2, Coal
Only- Nov11,
2004,11:40-
14:02
0.0000
0.0000
0.0000
0.0000
0.0002
0.0013
0.0000
0.0018
0.0658
0.0289
0.0011
0.0579
0.0000
0.0219
0.0000
0.0000
0.0000
0.00002
0.00075
0.0017
0.0000
0.0017
0.0605
0.0259
0.0019
0.0306
0.0000
0.0247
Run 3, Coal
Only- Nov11,
2004, 15:00-
17:25
0.0000
0.0000
0.0000
0.0000
0.0009
0.0226
0.0000
0.0025
0.0033
0.0213
0.0055
0.0204
0.0000
0.0317
0.0000
0.0000
0.0000
0.00004
0.00030
0.0034
0.0000
0.0017
0.0080
0.0351
0.0026
0.0217
0.0000
0.0316
Average,
Coal
Only
0.0000
0.0000
0.0000
0.0000
0.0005
0.0085
0.0000
0.0020
0.0238
0.0227
0.0027
0.0307
0.0000
0.0262
0.0000
0.0000
0.0000
0.00002
0.00047
0.0027
0.0000
0.0015
0.0427
0.0271
0.0021
0.0226
0.0000
0.0243
23
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ARCADIS
Source Testing Final
Report
Lehigh Cement
Table 3-8. Kiln #1 Stack HCI, C\~, HBr, and Br' Emissions Results
Emission Rate, mg/dscm
Analyte
HCI
cr
HBr
Br"
Analyte
HCI
cr
HBr
Br"
Run 1, Coal
Only - Nov
11,2004,
08:10-10:35
3.44
1.38
0.00
0.00
Run 1,
Carpet Co-
Fire - Nov
8, 2004,
08:50-11:14
6.01
1.72
0.00
0.00
Run 2,
Coal Only -
Nov 11,
2004,
11:40-
14:02
8.43
0.66*
0.00
0.00
Run 2,
Carpet Co-
Fire - Nov
8, 2004,
12:35-
15:02
5.51
0.91*
0.00
0.00
Run 3, Coal
Only - Nov
11,2004,
15:00-17:25
6.59
1.41
0.00
0.00
Run3,
Carpet Co-
Fire - Nov 8,
2004, 16:40-
18:40
2.72
0.03*
0.00
0.00
Average,
Coal Only
6.15
1.15
0.00
0.00
Average,
Carpet Co-
Fire
4.75
0.89
0.00
0.00
* - number is approximate as chromatographic interference prevented complete resolution of
chlorine
3.2.4 Dioxins and Furans Emissions Results
Dioxin and furan emissions results, as determined by EPA Method 23, are presented in
Tables 3-9 through 3-14. Test dates and times forTables 3-11 through 3-14 are the
same as those for Tables 3-9 and 3-10.
24
-------
Source Testing Final
Report
Lehigh Cement
Table 3-9: Dioxins and Furans Emission Data Summary, Kiln No. 1 Exhaust Stack-Coal
Only Testing using EPA M23
Test Date
Test Run Number
Test Times
Elapsed Sampling Time
Required Sampling Time
Process Data Summary
11/09/2004
1
07:50-11:18
180
11/09/04
2
07:50-11:18
180
11/10/04
3
11:50-15:15
180
240
Sampling/Stack Data
O2 Concentration, (% by volume, dry)
CO2 Concentration, (% by volume, dry)
Sample Volume, (dscf)
Required Sample Volume, (dscf)
Stack Gas Moisture, (%)
Stack Gas Temperature, (°F)
Volumetric Flow Rate, (dscfm)
Isokinetic Rate, (%)
Permitted Isokinetic Rate, (%)
4.9
26.5
171.607
4.9
26.5
173.375
5.3
26.3
168.972
144
18.7
396
77,837
96.8
20.5
396
76,073
96.8
18.6
393
77,510
95.7
90-110
Total Toxic Equivalent Dioxins/Furans as 2,3,7,8-TCDD Emission Results
Total D/F Emission Catch, (ng)
D/F Emission Rate, (Ib/hr)
D/F Emission Concentration, (ng/DSCM)
D/F Emission Concentration, (ng/DSCM @ 7% O2)
Allowable D/F Emission Concentration, (ng/DSCM
@ 7% O2)
0.0353
2.12 x10"9
7.26 x10"3
6.31 x10"3
N/A
0.0311
1.80x10"9
6.33 x10"3
5.52 x10"3
N/A
0.0418
2.54 x10"9
8.74 x10"3
7.80 x10"3
N/A
Total Dioxins/Furans (D/F) Emission Results
Total D/F Emission Catch, (ng)
D/F Emission Rate, (Ib/hr)
D/F Emission Concentration, (ng/DSCM)
D/F Emission Concentration, (ng/DSCM @ 7% O2)
Allowable D/F Emission Concentration, (ng/DSCM
@ 7% O2)
14.45
8.67 x10"7
2.97
2.58
N/A
12.64
7.34 x10"7
2.57
2.24
N/A
12.89
7.82 x10-7
2.69
2.40
N/A
Average
N/A
N/A
180
N/A
N/A
N/A
5.0
26.4
171.3
N/A
19.3
395
77,140
96.4
N/A
N/A
0.0361
2.15 x10"9
7.44 x10"3
6.54 x10"3
N/A
13.33
7.94 x10"7
2.74
2.41
25
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Source Testing Final
Report
Lehigh Cement
Table 3-10: Dioxinsand Furans Emission Data Summary, Kiln No. 1 Exhaust Stack-Co-fire
Testing using EPA M23
Test Date
Test Run Number
Test Times
Elapsed Sampling Time
Required Sampling Time
Process Data Summary
11/05/04
1
09:45-13:35
180
11/05/04
2
09:45-13:35
180
11/05/04
3
16:20-22:08
180
240
Sampling/Stack Data
O2 Concentration, (% by volume, dry)
CO2 Concentration, (% by volume, dry)
Sample Volume, (dscf)
Required Sample Volume, (dscf)
Stack Gas Moisture, (%)
Stack Gas Temperature, (°F)
Volumetric Flow Rate, (dscfm)
Isokinetic Rate, (%)
Permitted Isokinetic Rate, (%)
5.0
26.2
198.821
5.0
26.2
199.635
4.9
26.5
173.702
144
19.8
400
66,034
91.5
20.1
401
58,003
102.2
20.6
402
72,494
105.2
90-110
Total Toxic Equivalent Dioxins/Furans as 2,3,7,8-TCDD Emission Results
Total D/F Emission Catch, (ng)
D/F Emission Rate, (Ib/hr)
D/F Emission Concentration, (ng/DSCM)
D/F Emission Concentration, (ng/DSCM @ 7%
02)
Allowable D/F Emission Concentration, (ng/DSCM @ 7%
02)
0.0050
2.20 x10"10
8.91 x10"4
7.78 x10"4
N/A
0.0121
4.66 x10"10
2.51 x10"3
2.20 x10"3
N/A
0.0104
5.74 x10-10
2.11 x10"3
1.83x10"3
N/A
Total Dioxins/Furans (D/F) Emission Results
Total D/F Emission Catch, (ng)
D/F Emission Rate, (Ib/hr)
D/F Emission Concentration, (ng/DSCM)
D/F Emission Concentration, (ng/DSCM @ 7%
02)
Allowable D/F Emission Concentration, (ng/DSCM @ 7%
02)
3.79
1.67x10"7
0.673
0.588
N/A
4.14
1.59x10"7
0.732
0.642
N/A
3.28
1.81 x10-7
0.667
0.579
N/A
Average
N/A
N/A
180
N/A
N/A
N/A
5.0
26.3
190.719
N/A
20.2
401
65,510
99.6
N/A
N/A
0.0092
4.20x10"
10
1.72x10"3
1.60x10"3
N/A
3.74
1.69x10"7
0.661
0.603
26
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Source Testing Final
Report
Lehigh Cement
Table 3-11. Coal Only Dioxin/Furan Run-by-Run Emission Rates and Concentrations
Pollutant
Base-M23-l
Base-M23-2
Concentration
Emission Rate
Concentration
Emission Rate
s/hr
ng/dscm
Ib/hr
Ib/ton
B/hr
Ib/ton
Base-M23-3
Concentration
s/hr
ng/dscm
Em
Dioxins
2,3,7,8-TCDD
Other TCDD
1,2,3,7,8-PeCDD
Other PeCDD
1,2,3,4,7,8-HxCDD
1,2,3,6,7,8-HxCDD
1,2,3,7,8,9-HxCDD
OtherHxCDD
1,2,3,4,6,7,8-HpCDD
OtherHpCDD
1,2,3,4,6,7,8,9-OCDD
Total CDD
Furans
2,3,7,8-TCDF
Other TCDF
1,2,3,7,8-PeCDF
2,3,4,7,8-PeCDF
Other PeCDF
1,2,3,4,7,8-HxCDF
1,2,3,6,7,8-HxCDF
2,3,4,6,7,8-HxCDF
1,2,3,7,8,9-HxCDF
Other HxCDF
1,2,3,4,6,7,8-HpCDF
1,2,3,4,7,8,9-HpCDF
OtherHpCDF
1,2,3,4,6,7,8,9-OCDF
Total CDF
Total CDD/CDF
5.52E-06
3.73E-04
5.17E-07
4.84E-07
9.10E-06
O.OOE+00
O.OOE+00
O.OOE+00
O.OOE+00
2.17E-07
1.50E-07
O.OOE+00
O.OOE+00
O.OOE+00
3.89E-04
4.18E-02
2.82E+00
3.91E-03
3.66E-03
6.88E-02
O.OOE+00
O.OOE+00
O.OOE+00
O.OOE+00
1.64E-03
1.13E-03
O.OOE+00
O.OOE+00
O.OOE+00
2.94E+00
IDIV/0!
IDIV/0!
IDIV/0!
IDIV/0!
IDIV/0!
IDIV/0!
IDIV/0!
IDIV/0!
IDIV/0!
IDIV/0!
IDIV/0!
IDIV/0!
1.22E-08
8.22E-07
1.14E-09
1.07E-09
2.01E-08
O.OOE+00
O.OOE+00
O.OOE+00
O.OOE+00
4.78E-10
3.31E-10
O.OOE+00
O.OOE+00
O.OOE+00
8.57E-07
IDIV/0!
IDIV/0!
IDIV/0!
IDIV/0!
IDIV/0!
IDIV/0!
IDIV/0!
IDIV/0!
IDIV/0!
IDIV/0!
IDIV/0!
IDIV/0!
IDIV/0!
IDIV/0!
IDIV/0!
4.66E-06
3.14E-04
6.53E-07
3.90E-07
8.67E-06
1.67E-07
O.OOE+00
O.OOE+00
O.OOE+00
3.17E-07
1.56E-07
O.OOE+00
O.OOE+00
O.OOE+00
3.29E-04
3.60E-02
2.43E+00
5.05E-03
3.01E-03
6.71E-02
1.30E-03
O.OOE+00
O.OOE+00
O.OOE+00
2.45E-03
1.21E-03
O.OOE+00
O.OOE+00
O.OOE+00
2.54E+00
3.94E-04
2.98E+0
8.68E-07
IDIV/0!
3.33E-04
2.65E+0
1.03E-08
6.92E-07
1.44E-09
8.59E-10
1.91E-08
3.69E-10
O.OOE+00
O.OOE+00
O.OOE+00
6.99E-10
3.45E-10
O.OOE+00
O.OOE+00
O.OOE+00
7.25E-07
7.34E-07
3.72E-06
3.07E-04
6.80E-07
9.47E-07
1.47E-05
4.76E-07
3.74E-07
2.97E-07
O.OOE+00
2.07E-06
1.97E-06
O.OOE+00
O.OOE+00
2.97E-07
3.33E-04
2.82E-02
2.33E+00
5.16E-03
7.19E-03
1.12E-01
3.62E-03
2.84E-03
2.26E-03
O.OOE+00
1.57E-02
1.50E-02
O.OOE+00
O.OOE+00
2.26E-03
2.53E+00
fl)IV/0!
3.56E-04
2.71E+0
2.46E-
3.03E-0
O.OOE+
9.59E-0
O.OOE+
3.35E-
O.OOE+
4.25E-0
1.96E-0
2.18E-0
3.24E-0
5.21E-0
8.19E-0
6.77E-0
1.50E-0
2.09E-0
3.25E-0
1.05E-0
8.25E-
6.55E-
O.OOE+
4.57E-0
4.35E-0
O.OOE+
O.OOE+
6.55E-
7.34E-0
7.86E-0
27
-------
Source Testing Final
Report
Lehigh Cement
Table 3-12. coal Only Dioxin/Furan Toxic Equivalency Factors
Three Run Average
Concentration
g/hr
1.19E-07
6.91E-06
O.OOE + 00
1.64E-06
O.OOE + 00
5.06E-08
O.OOE + 00
7.91E-07
2.96E-07
3.95E-07
7.33E-07
1.09E-05
4.63E-06
3.31E-04
6.17E-07
6.07E-07
1.08E-05
2.15E-07
1.25E-07
9.91E-08
O.OOE + 00
8.69E-07
7.60E-07
O.OOE + 00
O.OOE + 00
9.91E-08
3.50E-04
ng/dscm
9.04E-04
7.73E-02
O.OOE + 00
1.24E-02
O.OOE + 00
3.85E-04
O.OOE + 00
6.01E-03
2.25E-03
3.00E-03
5.S8E-03
1.08E-01
3.53E-02
2.S3E + 00
4.71E-03
4.62E-03
8.26E-02
1.64E-03
9.47E-04
7.52E-04
O.OOE + 00
6.61E-03
5.78E-03
O.OOE + 00
O.OOE + 00
7.52E-04
2.67E + 00
Emission Rate
Ib/hr
2.61E-10
1.S2E-08
O.OOE + 00
3.61E-09
O.OOE + 00
1.12E-10
O.OOE + 00
1.74E-09
6.53E-10
8.71E-10
1.62E-09
2.41E-08
1.02E-08
7.30E-07
1.36E-09
1.34E-09
2.39E-08
4.73E-10
2.75E-10
2.18E-10
O.OOE + 00
1.92E-09
1.68E-09
O.OOE + 00
O.OOE + 00
2.18E-10
7.72E-07
lb/tona
NA
NA
NA
NA
NA
NA
NA
NA
NA
NA
NA
NA
NA
NA
NA
NA
NA
NA
NA
NA
NA
NA
NA
NA
NA
NA
NA
1989
Toxic
Equivalency
Factor
1.000
---
0.500
---
0.100
0.100
0.100
---
0.010
---
0.001
—
0.100
---
0.050
0.500
---
0.100
0.100
0.100
0.100
---
0.010
0.010
---
0.001
---
Toxic Equivalent Three Run Average
Concentration
g/hr
1.19E-07
NA
O.OOE + 00
NA
O.OOE + 00
5.06E-09
O.OOE + 00
NA
2.96E-09
NA
7.33E-10
1.27E-07
4.63E-07
NA
3.08E-08
3.03E-07
NA
2.15E-08
1.25E-08
9.91E-09
O.OOE + 00
NA
7.60E-09
O.OOE + 00
NA
9.91E-1 1
8.49E-07
ng/dscm
9.04E-04
NA
O.OOE + 00
NA
O.OOE + 00
3.85E-05
O.OOE + 00
NA
2.25E-05
NA
5.58E-06
9.71E-04
3.53E-03
NA
2.35E-04
2.31E-03
NA
1.64E-04
9.47E-05
7.52E-05
O.OOE + 00
NA
5.78E-05
O.OOE + 00
NA
7.52E-07
6.47E-03
Emission Rate
Ib/hr
2.61E-10
NA
O.OOE + 00
NA
O.OOE + 00
1.12E-1 1
O.OOE + 00
NA
6.53E-12
NA
1.62E-12
2.81E-10
1.02E-09
NA
6.80E-1 1
6.69E-10
NA
4.73E-1 1
2.75E-1 1
2.18E-1 1
O.OOE + 00
NA
1.68E-1 1
O.OOE + 00
NA
2.18E-13
1.87E-09
Ib/ton
NA
NA
NA
NA
NA
NA
NA
NA
NA
NA
NA
NA
NA
NA
NA
NA
NA
NA
NA
NA
NA
NA
NA
NA
NA
NA
NA
2.78E + 00
28
-------
Source Testing Final
Report
Lehigh Cement
Table 3-13. Carpet Co-Fire Dioxin/Furan Run-by-Run Emission Rates and Concentrations
H1-M23-1
Concentration
Pollutant
Dioxins
2,3,7,8-TCDD
Other TCDD
1,2,3,7,8-PeCDD
Other PeCDD
1,2,3,4,7,8-HxCDD
1,2,3,6,7,8-HxCDD
1,2,3,7,8,9-HxCDD
Other HxCDD
1,2,3,4,6,7,8-HpCDD
Other HpCDD
1,2,3,4,6,7,8,9-OCDD
Total CDD
Furans
2,3,7,8-TCDF
Other TCDF
1,2,3,7,8-PeCDF
2,3,4,7,8-PeCDF
Other PeCDF
1,2,3,4,7,8-HxCDF
1,2,3,6,7,8-HxCDF
2,3,4,6,7,8-HxCDF
1,2,3,7,8,9-HxCDF
Other HxCDF
1,2,3,4,6,7,8-HpCDF
1,2,3,4,7,8,9-HpCDF
Other HpCDF
1,2,3,4,6,7,8,9-OCDF
Total CDF
g/hr
O.OOE+00
4.22E-07
O.OOE+00
5.32E-07
O.OOE+00
O.OOE+00
O.OOE+00
6.86E-07
4.52E-07
4.26E-07
8.07E-07
3.33E-06
8.21E-07
6.97E-05
O.OOE+00
O.OOE+00
1.93E-06
1.02E-07
O.OOE+00
O.OOE+00
O.OOE+00
2.71E-07
2.37E-07
O.OOE+00
O.OOE+00
O.OOE+00
7.31E-05
ng/dscm
O.OOE+00
3.77E-03
O.OOE+00
4.74E-03
O.OOE+00
O.OOE+00
O.OOE+00
6.11E-03
4.03E-03
3.80E-03
7.19E-03
2.96E-02
7.32E-03
6.21E-01
O.OOE+00
O.OOE+00
1.72E-02
9.06E-04
O.OOE+00
O.OOE+00
O.OOE+00
2.42E-03
2.11E-03
O.OOE+00
O.OOE+00
O.OOE+00
6.51E-01
Emission Rate
Ib/hr
O.OOE+00
9.31E-10
O.OOE+00
1.17E-09
O.OOE+00
O.OOE+00
O.OOE+00
1.51E-09
9.97E-10
9.40E-10
1.78E-09
7.33E-09
1.81E-09
1.54E-07
O.OOE+00
O.OOE+00
4.26E-09
2.24E-10
O.OOE+00
O.OOE+00
O.OOE+00
5.97E-10
5.23E-10
O.OOE+00
O.OOE+00
O.OOE+00
1.61E-07
Ib/ton
IDIV/0!
IDIV/0!
IDIV/0!
IDIV/0!
IDIV/0!
IDIV/0!
IDIV/0!
IDIV/0!
IDIV/0!
IDIV/0!
IDIV/0!
IDIV/0!
IDIV/0!
IDIV/0!
IDIV/0!
IDIV/0!
IDIV/0!
IDIV/0!
IDIV/0!
IDIV/0!
IDIV/0!
IDIV/0!
IDIV/0!
IDIV/0!
IDIV/0!
IDIV/0!
IDIV/0!
H1-M23-2
Concentration
S/hr
O.OOE+00
9.87E-07
O.OOE+00
5.79E-07
O.OOE+00
O.OOE+00
O.OOE+00
4.53E-07
2.95E-07
2.91E-07
7.55E-07
3.36E-06
8.63E-07
6.52E-05
O.OOE+00
1.74E-07
2.39E-06
2.02E-07
1.15E-07
O.OOE+00
O.OOE+00
3.54E-07
2.74E-07
O.OOE+00
O.OOE+00
O.OOE+00
6.96E-05
ng/dscm
O.OOE+00
6.56E-03
O.OOE+00
5.87E-03
O.OOE+00
O.OOE+00
O.OOE+00
4.60E-03
2.99E-03
2.95E-03
7.66E-03
3.06E-02
8.76E-03
6.62E-01
O.OOE+00
1.77E-03
2.42E-02
2.05E-03
1.17E-03
O.OOE+00
O.OOE+00
3.59E-03
2.78E-03
O.OOE+00
O.OOE+00
O.OOE+00
7.06E-01
Emission Rate
Ib/hr
O.OOE+00
2.18E-09
O.OOE+00
1.28E-09
O.OOE+00
O.OOE+00
O.OOE+00
9.99E-10
6.50E-10
6.42E-10
1.66E-09
7.41E-09
1.90E-09
1.44E-07
O.OOE+00
3.84E-10
5.27E-09
4.46E-10
2.54E-10
O.OOE+00
O.OOE+00
7.80E-10
6.03E-10
O.OOE+00
O.OOE+00
O.OOE+00
1.53E-07
Ib/ton
IDIV/0!
IDIV/0!
IDIV/0!
IDIV/0!
IDIV/0!
IDIV/0!
IDIV/0!
IDIV/0!
IDIV/0!
IDIV/0!
IDIV/0!
IDIV/0!
IDIV/0!
IDIV/0!
IDIV/0!
IDIV/0!
IDIV/0!
IDIV/0!
IDIV/0!
IDIV/0!
IDIV/0!
IDIV/0!
IDIV/0!
IDIV/0!
IDIV/0!
IDIV/0!
IDIV/0!
H1-M23-3
Concentration
g/hr
O.OOE+00
9.29E-07
O.OOE+00
4.58E-07
O.OOE+00
O.OOE+00
O.OOE+00
2.19E-07
2.10E-07
O.OOE+00
6.44E-07
2.46E-06
9.74E-07
7.54E-05
4.56E-07
2.17E-07
2.41E-06
2.58E-07
O.OOE+00
O.OOE+00
O.OOE+00
3.66E-07
2.90E-07
O.OOE+00
O.OOE+00
O.OOE+00
8.04E-05
ng/dscm
O.OOE+00
7.54E-03
O.OOE+00
3.72E-03
O.OOE+00
O.OOE+00
O.OOE+00
1.77E-03
1.70E-03
O.OOE+00
5.22E-03
2.00E-02
7.91E-03
6.12E-01
3.70E-03
1.76E-03
1.95E-02
2.09E-03
O.OOE+00
O.OOE+00
O.OOE+00
2.97E-03
2.36E-03
O.OOE+00
O.OOE+00
O.OOE+00
6.52E-01
Emission Rate
Ib/hr
O.OOE+00
2.05E-09
O.OOE+00
1.01E-09
O.OOE+00
O.OOE+00
O.OOE+00
4.82E-10
4.62E-10
O.OOE+00
1.42E-09
5.42E-09
2.15E-09
1.66E-07
l.OOE-09
4.79E-10
5.31E-09
5.69E-10
O.OOE+00
O.OOE+00
O.OOE+00
8.06E-10
6.40E-10
O.OOE+00
O.OOE+00
O.OOE+00
1.77E-07
Ib/ton
IDIV/0!
IDIV/0!
IDIV/0!
IDIV/0!
IDIV/0!
IDIV/0!
IDIV/0!
IDIV/0!
IDIV/0!
IDIV/0!
IDIV/0!
IDIV/0!
IDIV/0!
IDIV/0!
IDIV/0!
IDIV/0!
IDIV/0!
IDIV/0!
IDIV/0!
IDIV/0!
IDIV/0!
IDIV/0!
IDIV/0!
IDIV/0!
IDIV/0!
IDIV/0!
IDIV/0!
Total CDD/CDF
7.64E-05
6.81E-01
1.68E-07
IDIV/0!
7.29E-05
7.37E-01
1.61E-07
IDIV/0!
8.28E-05
6.72E-01
1.83E-07
IDIV/0!
29
-------
Source Testing Final
Report
Lehigh Cement
Table 3-14. Carpet Co-Fire Dioxin/Furan Toxic Equivalency Factors
Three Run Average
C oncentration
g/hr
O.OOE + 00
7.79E-07
O.OOE + 00
5.23E-07
O.OOE + 00
O.OOE+00
O.OOE+00
4.52E-07
3.19E-07
2.39E-07
7.35E-07
3.05E-06
8.86E-07
7.01E-05
1.S2E-07
1.31E-07
2.24E-06
1.87E-07
3.84E-08
O.OOE + 00
O.OOE + 00
3.30E-07
2.67E-07
O.OOE + 00
O.OOE+00
O.OOE+00
7.43E-05
ng/dscm
O.OOE+00
5.96E-03
O.OOE+00
4.78E-03
O.OOE+00
O.OOE+00
O.OOE+00
4.16E-03
2.91E-03
2.2SE-03
6.69E-03
2.67E-02
7.99E-03
6.32E-01
1.23E-03
1.18E-03
2.03E-02
1.68E-03
3.89E-04
O.OOE+00
O.OOE+00
2.99E-03
2.42E-03
O.OOE+00
O.OOE+00
O.OOE+00
6.70E-01
Emission Rate
Ib/hr
O.OOE+00
1.72E-09
O.OOE+00
1.15E-09
O.OOE+00
O.OOE+00
O.OOE+00
9.97E-10
7.03E-10
S.27E-10
1.62E-09
6.72E-09
1.95E-09
1.S5E-07
3.35E-10
2.88E-10
4.94E-09
4.13E-10
8.46E-11
O.OOE+00
O.OOE+00
7.28E-10
5.89E-10
O.OOE+00
O.OOE+00
O.OOE+00
1.64E-07
lb/tona
NA
NA
NA
NA
NA
NA
NA
NA
NA
NA
NA
NA
NA
NA
NA
NA
NA
NA
NA
NA
NA
NA
NA
NA
NA
NA
NA
1989
Toxic
Equivalency
Factor
1.000
0.500
0.100
0.100
0.100
...
0.010
...
0.001
...
0.100
...
0.050
0.500
...
0.100
0.100
0.100
0.100
0.010
0.010
...
0.001
Toxic Equivalent Three Run Average
C oncentration
g/hr
O.OOE+00
NA
O.OOE+00
NA
O.OOE+00
O.OOE+00
O.OOE+00
NA
3.19E-09
NA
7.35E-10
3.92E-09
8.86E-08
NA
7.60E-09
6.53E-08
NA
1.87E-08
3.84E-09
O.OOE+00
O.OOE+00
NA
2.67E-09
O.OOE+00
NA
O.OOE+00
1.87E-07
ng/dscm
O.OOE+00
NA
O.OOE+00
NA
O.OOE+00
O.OOE+00
O.OOE+00
NA
2.91E-05
NA
6.69E-06
3.58E-05
7.99E-04
NA
6.17E-05
5.89E-04
NA
1.68E-04
3.89E-05
O.OOE+00
O.OOE+00
NA
2.42E-05
O.OOE+00
NA
O.OOE+00
1.68E-03
Emission Rate
Ib/hr
O.OOE+00
NA
O.OOE+00
NA
O.OOE+00
O.OOE+00
O.OOE+00
NA
7.03E-12
NA
1.62E-12
8.65E-12
1.95E-10
NA
1.67E-11
1.44E-10
NA
4.13E-11
8.46E-12
O.OOE+00
O.OOE+00
NA
5.89E-12
O.OOE+00
NA
O.OOE+00
4.12E-10
lb/tona
NA
NA
NA
NA
NA
NA
NA
NA
NA
NA
NA
NA
NA
NA
NA
NA
NA
NA
NA
NA
NA
NA
NA
NA
NA
NA
NA
30
-------
Source Testing Final
Report
Lehigh Cement
3.2.5 GEMS Emissions Results
GEMS measurements of carbon monoxide sulfur dioxide, and nitrogen oxides were
made both prior to and during the extractive sampling runs. The results are reported in
Table 3-15. Carbon monoxide emissions were determined by EPA Method 10, sulfur
dioxide emissions were determined by EPA Method 6C, and nitrogen oxides emissions
were determined by EPA Method IE. Oxygen and carbon dioxide emissions, as
determined by EPA Method 3 A are also presented. Table 3-16 presents a preliminary
look at GEMS and production data.
Table 3-15. Kiln #1 Stack CEMS Results
Date/Time
11/1/2004/12:43-
14:52
11/2/2004/08:35-
11:52
11/2/2004/12:02-
15:03
11/2/2004/15:12-
16:34
11/3/2004/08:11-
11:12
11/3/2004/11:20-
14:25
11/3/2004/14:34-
16:13
11/4/2004/08:00-
10:05
11/4/2004/10:14-
11:50
11/4/2004/11:59-
14:58
11/5/2004/07:46-
12:48
11/5/2004/13:06-
13:33
11/5/2004/15:34-
20:05
11/8/2004/08:16-
Fuel
Various*
Various
Various
Various
Various
Various
Various
Various
Various
Various
Carpet
Co- Fire
Carpet
Co- Fire
Carpet
Co- Fire
Carpet
Ru
n
1
1
2
3
1
2
3
1
2
3
1
2
3
1
02, %
7.6
4.7
4.3
4.6
4.2
5.7
4.8
5.3
5.1
4.7
5.0
4.9
4.9
5.3
CO2,
20.5
27.1
27.7
27.7
27.0
25.0
25.6
25.5
26.4
26.5
26.2
26.0
26.5
25.7
SO2, ppmv
2129
202
300
130
1366
46
104
434
39
149
398
306
321
23
CO, ppmv
328
128
130
124
193
100
121
450
110
117
129
129
121
95
NOX, ppmv
387
891
603
852
1284
1004
774
751
1007
756
866
436
585
990
31
-------
Source Testing Final
Report
Lehigh Cement
Date/Time
11:10
11/8/2004/11:26-
15:03
11/8/2004/15:16-
18:07
11/8/2004/18:24-
18:41
11/9/2004/06:49-
11;18
11/9/2004/11:38-
13:53
11/10/2004/07:13-
11:19
11/10/2004/11:37-
13:50
11/10/2004/15:22-
16:53
11/11/2004/07:50-
09:55
11/11/2004/10:16-
12:18
11/11/2004/12:38-
14:17
11/11/2004/14:58-
17:00
11/12/2004/09:46-
10:19
11/12/2004/13:00-
15:03
11/12/2004/15:19-
17:20
11/12/2004/17:35-
18:37
Fuel
Co- Fire
Carpet
Co- Fire
Carpet
Co- Fire
Carpet
Co- Fire
Coal
Only
Coal
Only
Coal
Only
Coal
Only
Coal
Only
Coal
Only
Coal
Only
Coal
Only
Coal
Only
Carpet
Co- Fire
Carpet
Co- Fire
Carpet
Co- Fire
Carpet
Co- Fire
Ru
n
2
3
4
1
2
1
2
3
1
2
3
4
1
2
3
4
02, %
5.0
5.0
5.5
4.9
5.9
5.0
5.3
4.6
4.9
4.9
4.2
4.9
5.0
5.1
5.0
5.3
C02,
26.2
26.1
26.1
26.5
24.5
25.1
26.3
26.3
26.7
26.9
25.3
26.9
26.5
26.3
26.6
26.2
SO2, ppmv
72
32
2
2
24
34
-3
44
6
2
115
15
136
121
138
1
CO, ppmv
111
117
89
90
81
112
115
130
101
103
121
110
116
120
127
106
NOX, ppmv
732
929
973
889
1470
1173
800
809
900
502
766
906
967
830
733
819
* - a number of fuel combinations were used as shakedown runs of the carpet feed system were being
performed
32
-------
Source Testing Final
Report
Lehigh Cement
Table 3-16. Preliminary Lehigh CEMSand Production Analyzer Data
Carpet Feed Rate = 2.2 TPH
Carpet Run #1 -11/5/04
Carpet Run#2- 11/8/04
Carpet Run#3- 11/1 2/04
Carpet Run Averages
Baseline Run # 1 -11/9/04
Baseline Run#2- 11/1 0/04
Baseline Run # 1 -11/11/04
Baseline Run Averages
Carpet
Burned
(tons)
32
27
33
0
0
0
0
Opacity
(%)
1.1
2.1
1.9
1.7
2.1
2.6
1.4
2.0
NOx
(ppm)
792.4
927.3
981.5
900.4
1115.5
1089.8
846.8
1017.4
NOx
( Ibs/hr )
517.0
599.0
654.1
590.0
681.6
629.0
572.9
627.8
Dry O2
(%)
4.7
4.9
4.7
4.8
5.3
6.2
4.5
5.3
Wet O2
(%)
4.0
4.1
4.1
4.1
4.3
5.4
4.0
4.6
Moisture
(%)
14.9
15.6
12.0
14.2
18.4
18.3
8.1
14.9
Baghouse
Inlet Temp.
(Deg.F)
408.2
406.7
412.6
409.2
406.1
405.3
403.2
404.9
Stack Flow
( KACFM )
171.1
172.8
166.7
170.2
167.9
156.9
163.5
162.8
Stack Flow
( KDSCFH )
5417.9
5393.1
5514.6
5441 .9
5119.8
4847.3
5612.9
5193.3
Stack Temp.
(Deg.F)
392.8
396.2
384.5
391.2
387.7
384.7
387.5
386.6
Stack Press.
( in. HG )
29.9
29.9
29.9
29.9
29.9
31.2
29.9
30.3
Kiln
Amps
( amps )
23.0
23.1
21.3
22.5
24.0
22.7
21.4
22.7
Chain Gas
Temp.
( Deg. F )
1533.0
1496.8
1484.6
1504.8
1482.7
1486.8
1480.1
1483.2
Coal
Feed
(TPH)
9.5
9.8
9.5
9.6
11.0
10.3
10.6
10.6
Raw
Feed
(TPH)
111.5
113.5
112.5
112.5
117.0
107.4
114.7
113.0
Clinker
Production
(TPH)
71.9
73.3
72.6
72.6
75.5
69.3
74.0
72.9
Combustion
(%)
0.1
0.1
0.1
0.1
0.1
0.1
0.1
0.1
Kiln
NOx
(ppm)
1019.3
1070.1
1099.6
1063.0
1338.6
1257.3
984.8
1193.6
Kiln
O2
(%)
1.8
1.7
1.8
1.8
1.8
1.9
1.6
1.8
Pyrometer
( Deg. F )
2393.7
2464.2
2563.5
2473.8
2569.7
2567.8
2449.6
2529.0
Kiln
Speed
(RPH)
93.2
95.2
95.9
94.8
98.5
89.7
95.9
94.7
Tire
Feed
Ibs/Rev.
0
0
0
0
0
0
0
0
33
-------
Source Testing Final
Report
Lehigh Cement
3.3 Field Test Changes and Problems
3.3.1 Variation from Test Methods and/or Planned Activities
As mentioned earlier, process upsets and delays lead to several on-the-fly changes to
the original test plan as detailed in the QAPP. The major change was to drop the low
carpet co-fire condition. The single carpet co-fire rate decided upon was the maximum
sustainable rate of 2.2 long tons per hour. Also, GARB Method 501/EPA Method 202
were substituted for Modified EPA Method 201A called for in the QAPP. This allowed
the collection of condensable particulate matter in addition to PMi0 and saved
considerable project resources.
Events which affected the sampling program were:
1.) On 11/5/04 the kiln went down at ~13:30 and was back on line at load at <
this period was between sampling runs.
45:50;
2.) On 11/8/04 the data GEMS collection program froze and had to be re-started; a bias
check was performed and data collection resumed with Run 4. Power was lost on the
stack at ~17:30 causing a pause in sampling; it was restored at ~ 18:15 and testing
resumed. The kiln went down at ~ 18:30 with 55 minutes left in the Carpet Co-Fire
Runs 3 of M26A and M29; these runs were nevertheless analyzed and reported here.
3.) On 11/9/04 the kiln went down at ~13:45. At ~16:00 the kiln operator said the kiln
would not be up for several more hours. Over two hours remained in Coal Only M23
Run 3; it was aborted and repeated on 11/10/04.
4.) On 11/10/04 the SO2 monitor was changed from 1000 ppmv to 100 ppmv at the
direction of Rob Small of PA DER.
5.) On 11/11/04 the SO2 monitor was over ranged on the 100 ppmv range at ~12:53
during Run 3; it was changed to the 500 ppmv range and returned to service at ~ 13:36
without re-calibration. For the remainder of Run 3 the SO2 results were multiplied by 5
to make them correct. The SO2 monitor was re-calibrated for the 500 ppmv range for
Run 4.
6.) The kiln went down at ~ 17:00 with no hope of being back on line sooner than
several hours. This led to the cancellation of Coal Only GARB M501/EPA M202 Run
3.
34
-------
Source Testing Final
Report
Lehigh Cement
4. Sampling and Analytical Procedures
4.1 Test Methods
The test methods used in this test program were: EPA Method 5 (front half) combined
with EPA Method 26A (back half) for filterable particulate/HCl, Cl", HBr, Br"; EPA
Method 29 for RCRA/CAA metals (Sb, As, Ba, Be, Cd, Cr, Co, Pb, Mn, Hg, Ni, Se,
Ag); EPA Method 23 for dioxins/furans; GARB Method 501 (front half) combined
with EPA Method 202 (back half) for PMi0 participate, particle size distribution, and
condensable particulate matter (neither N2 purging for organics removal or NH4OH
addition for sulfate correctionwere used due to the fact that condensable organics were
of interest and our experience with the sulfate correction procedure has shown
overcorrection, i.e., negative values); EPA Method 3A for O2/CO2; EPA Method 6C
for SO2; EPA Method 7E for NOX; and EPA Method 10 for CO. EPA Method 205 was
used to verify the proper performance of the diluter used to blend GEMS calibration
gases. All laboratory analytical procedures were those called for in the corresponding
test method. See Appendix 5 for complete texts of the sampling and analytical
methods.
4.2 Analytical Methods
All analytical methods employed in this testing program were those contained in or
required by the test methods used. They are further detailed in the individual laboratory
analytical reports which can be seen in Appendix 4.
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Source Testing Final
ARCADIS Report
Lehigh Cement
36
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Source Testing Final
Report
Lehigh Cement
5. Internal QA/QC Activities
QA/QC procedures followed were those in the individual sampling and analytical
methods. See individual methods (Appendix 4) for further information.
5.1 QA/QC Problems
No known QA/QC problems occurred during this test program.
5.2 QA Audits
QA audit samples, as procured by PA DEP, were submitted for this test program. They
consisted of audit samples for M26A submitted to Resolution Analytics and those for
M29 submitted to First Analytical Laboratories. The audit samples were delivered to
ARCADIS G&M and submitted to the contract labs along with the samples from the
test program. The results are shown in Table 5-1. According to PA DEP personnel, the
labs passed the audits.
Table 5-1. QA Audit Samples Results
Laboratory
Resolution
Resolution
First Analytical
First Analytical
First Analytical
First Analytical
First Analytical
First Analytical
First Analytical
First Analytical
First Analytical
EPA Audit Sample
Number
M-1536
M-1890
AM-01111
AM-01111
AM-01111
AM-01111
Fil-3732
Fil-3732
Fil-3732
Fil-3732
HG-0846
Analyte
Cl
Cl
As
Cd
Cr
Pb
As
Cd
Cr
Pb
Hg
Concentration
53.1 mg/L
14.7mg/L
8.63 ug/mL
6.83 ug/mL
8.53 ug/mL
9.60 ug/mL
20.1 ug
33.8 ug
29.3 ug
38.3 ug
97.6 ng/mL
Blank Filter
-
-
-
-
-
-
<0.5 ug
<0.02 ug
0.15 ug
<0.5 ug
-
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&EPA
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