AP42 Section:

Reference:

Title:

11.16

6

Source Emission Tests, Gold Bond Building Products, EMB-80-GYP-5, U. S. Environmental Protection Agency, Research Triangle Park, NC, December 1980.

1

r United States Office of Air Quality EMB Report 80-GYP-5 Enyironmental Protection Planning and Standards December 1980 Agency Research Triangle Park NC 2771 1

11-A-20

GYPSUM

AP-42 S e c t i o n 6 . 1 4 Reference Number

6

MANUFACTURING / /

, -.

Environmental Consultants

UNITED STATES ENVIRONMENTAL PROTECTION AGENCY EMISSIONS MEASUREMENT BRANCH

MAIL DROP 13 RESEARCH TRIANGLE PARK, NORTH CAROLINA 27711

FINAL REPORT

for an

EMISSION TEST PROGRAM conducted at

GOLD BOND BUILDING PRODUCTS 1040 CANAL BLVD.

RICHMOND, CA 94804

Prepared by'

YORK RESEARCH CORPORATION

STAMFORD, CONNECTICUT 06906 CNE RESEARCH DRIVE

CONTRACT NUMBER 68-02-2819

WORK ASSIGNMENT 29

EPA PROJECT NUMBER 80-GYP-5

YRC PROJECT NUMBER 01-9517-29

March 30, 1981

Yirk Research Carparatian One Research Drive. Stamford. Connecticut 06906 -Telephone: (2031 325-1371 - TWX. 710-474-3947

PREFACE -.

The work r epor t ed he re in w a s conducted by personnel from York Research Corporation ( Y R C ) , Radian Corporat ion and t h e United S t a t e s Environmental P r o t e c t i o n Agency (USEPA).

The scope of t h e work, i s sued under EPA Cont rac t Number 68-02-2819,

Work Assignment Number 2 9 , w a s under t h e supe rv i s ion of YRC

P r o j e c t Director , M r . James W. Davison. M r . Roger A. Kniskern, YRC P r o j e c t Manager, was r e spons ib l e f o r summarizing t h e t es t and a n a l y t i c a l da t a contained i n t h i s r e p o r t . Analyses of t h e samples were performed a t t h e YRC l abora to ry i n Stamford, Connect icut under t h e d i r e c t i o n of M r . Robert Q. Bradley.

M r . Michael Pa lazzolo of Radian Corporat ion was r e spons ib l e f o r monitor ing t h e process ope ra t ions dur ing t h e t e s t i n g program. Personnel from Radian Corporat ion w i l l provide t h e Process Descr ip t ion and Operat ions s e c t i o n of t h i s r e p o r t .

P l a n t Manager, Robert B r i t t and P l a n t Super in tendent , Michael Ward of Gold Bond were very h e l p f u l and coopera t ive throughout t h e t es t program. Thei r a s s i s t a n c e i s g r e a t l y apprec i a t ed .

M r . Dennis Holzschuh of t h e O f f i c e of A i r Q u a l i t y Planning and Standards , Emission Measurement Branch, USEPA, se rved as Tech-

n i c a l Manager and was r e spons ib l e f o r coord ina t ing t h e emission

tes t program.

LIST OF TABLES

1 - Summary of Emission T e s t R e s u l t s - Baqhouse I n l e t -

2 - Summary of Emission T e s t R e s u l t s - Baghouse I n l e t -

3 - Summary of Emission T e s t R e s u l t s - Baqhouse O u t l e t -

4 - Summary of Emission T e s t R e s u l t s - Baqhouse O u t l e t -

Engl i sh Un i t s

Metric Un i t s

Engl i sh Un i t s

Metric Uni t s

5 - Comparison of I n l e t and O u t l e t G a s Stream and P a r t i c u l a t e D a t a - Engl i sh U n i t s

P a r t i c u l a t e Data - Metric Un i t s 6 - Comparison of I n l e t and O u t l e t G a s Stream and

7 - P a r t i c l e S i z e D i s t r i b u t i o n - Baqhouse I n l e t

8 - . P a r t i c l e S i z e D i s t r i b u t i o n - Baqhouse Out le t

9 - Summary of V i s i b l e Emissions Observa t ions - #1 C a l c i n e r Baqhouse O u t l e t

1 0 - Summary of V i s i b l e Emissions Observa t ions - Sto rage Bin Area - Stucco S i l o

S to rage Bin Area - Conveyor 11 - Summary of F u g i t i v e Emissions Observa t ions -

1 2 - Summary of Emission T e s t s Conducted

13 - Cont ro l Equipment Parameters

1 4 - Bag Replacement Schedules

LIST. OF FIGURES

2 . 1 2 . 2 3.1 3.2 4.1 4 . 2

4 . 4

4.5 5 . 1 5.2 5.3

Par t ic le S ize D i s t r i b u t i o n - Baghouse I n l e t P a r t i c l e S i z e D i s t r i b u t i o n - Baghouse O u t l e t Block F l o w Diagram Calcidyne F la sh Calciner T e s t P o r t and Sampling P o i n t Locat ions - Baghouse I n l e t T e s t P o r t and Sampling P o i n t Locat ions - Baghouse O u t l e t P o s i t i o n of Observer - Stucco S i l o P o s i t i o n of Observer - Conveyor Modified P a r t i c u l a t e Sampling Tra in Andersen S t a c k Sampler Andersen Sampling T r a i n

x

1.0 INTRODUCTION

Sec t ion I11 of t h e Clean A i r A c t of 1 9 7 0 charges t h e Adminis- t r a t o r of t h e United S t a t e s Environmental P ro tec t ion Agency (USEPA) wi th t h e r e s p o n s i b i l i t y of e s t a b l i s h i n g f e d e r a l s t an - dards of performance f o r new s t a t i o n a r y sources which may s ig - n i f i c a n t l y c o n t r i b u t e t o a i r p o l l u t i o n . When promulgated, t hese s tandards of performance f o r new s t a t i o n a r y sources (NSPS) w i l l r e f l e c t t h e degree of emission l i m i t a t i o n achiev- ab le through a p p l i c a t i o n of t h e b e s t demonstrated emission c o n t r o l technology. To assemble t h i s background informat ion , t h e USEPA u t i l i z e s emission d a t a obta ined from c o n t r o l l e d sources involved i n t h e p a r t i c u l a r i n d u s t r y under cons ide ra t ion , i n t h i s case , t h e gypsum indus t ry .

?' 45

Based on t h e above c r i t e r i a , t h e USEPA's Of f i ce of A i r Q u a l i t y Planning and Standards (OAQPS) s e l e c t e d Gold Bond Building Products i n Richmond, C a l i f o r n i a a s a s i t e t o conduct an emission tes t program. York Research Corpora t ion ( Y R C ) , under EPA

Cont rac t Number 68-02-2819, Work Assignment 2 9 , was reques ted t o conduct t h e t e s t program. The r e s u l t s - o f t h i s program a r e t o provide a po r t ion of t h e emission d a t a r equ i r ed f o r e s t a b l i s h - ing t h e NSPS f o r t h e gypsum indus t ry .

The #1 f l a s h c a l c i n e r a t Gold Bond w a s t e s t e d . Emissions from t h e c a l c i n e r are c o n t r o l l e d by a baghouse.

Emission sampling w a s conducted dur ing t h e week of J u l y 14, 1980 a t t h e baghouse i n l e t and o u t l e t using USEPA Reference Methods. Emissions from t h e #1 c a l c i n e r were observed dur ing sampling t o determine opac i ty .

Emissions obse rva t ions were a l s o conducted a t t h e s t o r a g e b in a rea .

-1-

2.0 SUMMARY AND DISCUSSION OF TEST RESULTS

2.1 Particulate Tests

The gas stream and particulate data and results are summarized in Tables 1 through 4. Due to technical problems (see 5.0 Sampling and Analytical Procedures) only two tests were run simultaneously at the inlet and outlet. The sequence of testing is shown below:

Date: 7/15 7/16 7/16 7/16 Test 1 Test 2 Test 3

Inlet 1524-1526* Test 17 09-2016 0916-1057 1248-1412 Times

Outlet Test run Test 1 Test 2 Test 3 Test was voided Times 0926-1044 1327-1517 1612-1754

replaces the first outlet test run

* Unit shut down

Results of these two tests are presented for comparison in Tables 5 and 6. The baghouse removal efficiencies were calculated from the particulate concentration. The average removal efficiency was 99.97%.

2.2 Particle Size Distribution Tests

The results of the particle size distribution tests are presented in Tables 7 and 8 and Figures 2-1 and 2-2.Three test runs were conducted at the inlet and one test run was conducted at the outlet.

2.3 Observations of Emissions

Throughout the particulate testing, a certified observer con- ducted visual tests to determine the opacity of the emissions at the baghouse outlet. Average opacity readings for six

-2-

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TABLE 7

PARTICLE S I Z E D.ISTRIBUTI0N BAGHOUSE INLET

GOLD BOND BUILDING PRODUCTS . RICHMOND, CALIFORNIA

P a r t i c u l a t e P a r t i c l e Mass i n s i z e

T e s t T i m e t i o n - T o t a l Range ( % of T o t a l ) # Date (sec) gr/DSCF (Microns)

1 7 / 1 5 / 8 0 30 1 1 . 9 6 7 8 >7 .05 5 8 . 5 1

1 . 0 5 - 4 . 3 7 1 0 . 2 7

4 .37-2 .94 1 1 . 6 5

2 . 9 4 - 1 . 9 8 6 . 9 2

1 . 9 8 - 1 . 2 5 6 . 3 5

1 . 2 5 - 0 . 6 0 4 . 5 5

0 . 6 0 - 0 . 3 5 1 . 0 6

0 . 3 5 - 0 . 2 0 0 . 2 9

< 0 . 2 0 0 . 3 9

2 7 / 1 6 / 8 0 20 8 . 9 0 5 6 1 > 8 . 3 0 4 4 . 4 9

T e s t Concentra- S i z e range

8 . 3 0 - 5 . 1 6 1 5 . 2 6

5 . 1 6 - 3 . 4 8 1 7 . 4 3

3 . 4 8 - 2 . 3 5 8 . 5 3

2 . 3 5 - 1 . 4 9 1 1 . 4 0 1 . 4 9 - 0 . 7 2 5 . 8 8

0 . 7 2 - 0 . 4 2 2 . 0 9

0 . 4 2 - 0 . 2 6 0 . 2 4

< 0 . 2 6 1 . 4 6 ~~

3 7 / 1 6 / 8 0 20 6 . 8 0 1 1 3 > 8 . 9 0 2 3 . 8 9

8 . 9 0 - 5 . 5 4 1 7 . 4 4

5 . 5 4 - 3 . 7 3 2 0 . 2 3

3 . 7 3 - 2 . 5 3 16 .33 2 . 5 3 - 1 . 6 0 1 1 . 4 9 1 . 6 0 - 0 . 7 8 5 . 6 5

0 . 7 8 - 0 . 4 6 1 . 9 3

0 . 4 6 - 0 . 2 8 0 . 8 6

c 0 . 2 8 2 . 1 8

-9-

T e s t # Date

1

-

7/16/80

. TABLE 8

PARTICLE S I Z E DISTRIBUTION

GOLD BOND BUILDING PRODUCTS RICHMOND, CALIFORNIA

BAGHOUSE OUTLET

' e s t Pa r t i cu la t e ' i m e C o n c e n t r a t i o n - m i n ) T o t a l gr /DSCF

12 0 0.02168

Par t ic le S i z e Mass i n s i z e R a n g e ( m i c r o n s )

>8.03 8.03-4.99 4.99-3.36 3.36-2.27 2.27-1.44 1.44-0.69 0.69-0.41 0.41-0.25 ~ 0 . 2 5

range ( % )

10.96 9.93

10.98 9.67

11.19 9.86

10.38 17.44 9.58

-10-

PARTICLE S IZE D ISTRIBUTION

100.0

5a0

aao 10.0

JQO

400

2q0

Ion 8.0 'ii 8.0 0 7.0 v)

2 0.0 0 c

z 8.0 2

1

K

P

1.0 0.9

0.8

0.7

0.6

0.5

0.4

0.2

0.1

CUMULATIVE PER CENT, B Y WEIGHT LESS THAN(Dp)

FIGURE 2.1

-11- ~~

PARTICLE S I Z E D ISTRIBUTION

100.0

e a 0 70.0

%lo

sa0

4OD

aw

2 M

IM 0.0

ao 0 7.0 v)

2 8.0 0 a 5 . 0

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0.7

0.6

0.5

0.4

0.3

0.Z

0.1

CUMULATIVE PER CENT B Y WEIGHT LESS THAN(Dp)

FlCiURE 2.2 .

-12-

L

minute in te rva ls are presented i n Table 9 . The v i s u a l tests were conducted f o r vary ing l eng ths of time, but i n a l l cases they included t h e o u t l e t p a r t i c u l a t e t es t pe r iod .

Visua l tes ts were a l s o conducted a t t h e s to rage b in a r e a . Three hours of opac i ty readings w e r e conducted by a c e r t i f i e d observer a t t h e s tucco s i l o . The frequency of f u g i t i v e emiss ions from a conveyor w a s a l s o determined. This t es t w a s a l s o conducted f o r t h r e e hours. The r e s u l t s of t h e s e tests a r e presented i n Tables 1 0 and 11.

*

-13-

TABLE 9 SUMMARY OF VISIBLE EMISSIONS OBSERVATIONS

+1 CALCINER BAGHOUSE OUTLET

Gold Bond Bu i ld ing Products Richmond, C a l i f .

TEST la 2 3 qd DATE 7/15/80 7/16/80 7/16/80 7/16/80 TIME 16 55- 2 0 17b 0926-1056 1250-1516 1620-1754

- A V E R A G E O P A C I T Y ( % ) - SIX MINUTE

INTERVAL

1 2 3 4 5 6 7

9 10

a

11 12 13 14 15 16 17 18 19 20 21 22 23 24 25

0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0

O C OC OC OC OC 0 OC 0 0 0 0 OC OC OC 0 O*

26 O*

0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 O*

0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 O*

a O u t l e t p a r t i c u l a t e t e s t run subsequen t ly voided , b . . Unit shut down f o r approx. 1 hour .

During this 6 minute i n t e r v a l v i s i o n obscured by steam plume. Some read ings were assumed t o remain zero. O u t l e t p a r t i c u l a t e t e s t i n g o n l y . I n t e r v a l less than 6 minu tes .

*

-14- ~ ~ ~ ~~~~

SUMMARY OF VISIBLE EMISSIONS OBSERVATIONS STORAGE BIN AREA - STUCCO SILO

Gold Bond Building Products Richmond, Calif.

Test 1 Date 1 2 3 7/15/80 7/16/80 7/16/80

Time 1130-1230 1100-1200 1520-1620 - A V E R A G E O P A C I T Y ( % ) -

Six Minute Interval

1 0 0 0

2

3

4

5

6

7

8

9

10

0

1.25

0

0

0

0

0

0

0

0

0

0

0

0

0

1.25

2.08

0

-15-

TABLE 11

SUMMARY OF FUGITIVE EMISSIONS OBSERVATIONS STORAGE BIN AREA - CONVEYOR Gold Bond Building Products

Richmond, Calif.

. ..

...

Date: July 16, 1980

Observation Period

1400-1420 1425-1445 1450-1510 1515-1535 1540-1600 1605-1625 1630-1650 1655-1715 1720-1740

Fugitive Emissions Observed (min)

Accumulated Observation Time (mid

Total Emission Time (min) = 0 Total Observation Time (mid = 180 Fugitive Emission Frequency = 0%

-16-

20 40 60 80

100 120 140 160 180

3. o PROCESS DESCRIPT-I~N ARD -oPE-T~;~TION

3 . 1 Plant Description The Gold Bond B u i l d i n g Products Richmond, Califor i a lant produces

wallboard from gypsum ore mined i n Mexico. plant by ocean-going freighter. process used a t the Richmond p l a n t i s shown i n Figure 3 - L Ore stockpiled a t the plant i s crushed t o about minus 5 cm ( 2 inches) and then dried and ground t o about 90 percent minus 100 mesh i n a g r i n d i n g mill. The ground crude gypsum, primarily calcium sulfate dihydrate (CaSO$2H20), i s heated t o around 571K (300'F) t o remove 75 percent of i t s water of hydration and thus form calcium sulfate hemihydrate (CaSO4. y 2 O ) . process i s known as calcining. w i t h starch, water, and other additives t o form a slurry. spread between two paper sheets and formed i n t o wet wallboard. wallboard i s subsequently dried i n a multi-deck kiln, trimmed to the correct size, and shipped t o distributors. 3 .2 Process Equipment Tested

Table = . A brief description of the major processing equipment tested a t the plant i s provided i n the fo l lowing sections.

The ore i s shipped to the A simplified f low diagram for the

This

The slurry i s The

The calcined gypsum o r stucco i s mixed

The emission t e s t s conducted a t the Richmond plant are shown i n

Calcidyne U n i t The calciner used a t the Richmond p l a n t i s a d i rec t contact f lash

The Calcidyne u n i t calciner of National Gypsum's own patented design. i s a continuous calciner i n which gypsum is calcined t h r o u g h d i rec t contact w i t h hot gases. Figure 13.2.

~ t u c c o Storage The stucco storage and transfer system used a t the p l a n t employs

A schematic diagram of the u n i t i s shown i n

conventional screw conveyors and bucket elevators t o transfer stucco from the Calcidyne units to a 318 Mg (350 t o n ) stucco storage s i l o and from the storage s i lo t o the board forming l ine.

- -17-

*

TABLE 12

EMISSION TESTS CONDUCTED AT GOLD BOND RICHMOND, CALIFORNIA PLANT

Process Tested Date Control Test Type In1 e t Outlet Method Test Test

Direct contact 7/15/80 Fabric P a r t i cul a t e 3 EPA-5 3 EPA-5 cal c i ner F i 1 t e r loading

Direct contact 7/16/80 Fabric calciner F i l t e r

Stucco storage 7/16/80 Fabric s i lo F i 1 t e r

Par t ic le size 3 Andersen 1 Andersen

emissions V i si ble -- EPA-9

V i si ble emissions

Stucco t ransfer 7/16/80 Capture Visible system (bucket head/ emissions elevator and screw Fabric conveyor) F i l t e r

-- EPA-9

EPA- 22

-18 - i

Mexi can S h i p

Covered 3 Stockpile

._----- J

> stucco Transfer,

e . Baghouse ---) Air Flow j Process Flow

Board ---- - J stucco Storage )Mixing and S i lo Forming

~

Warehouse 7 I Vent I

Drying

I - Vent I

Knife F1 ash

Vent ~. Calciners Vent U ----“I I’ *m

Block flow diagram for Richmond board plant.

F i g u r e 3.1

- 1 -19-

I

L I n l e t t o fabr ic f i l t e r d u s t col lector

C S ’

C L -

Product discharge t o conveyor

Calcidyne f lash calciner .

Figure 3 . 2

-20- i

. 3.3 Emission Controls

control gypsum particulate emissions. Dust laden gases exiting the direct contact calciners are vented to separate baghouses. Emissions

Fabric f i l t e r d u s t collectors a re used a t the Richmond plant t o

from screw conveyors and bucket elevators are also vented to fabric f i l t e r dust collectors. Emissions from the stucco storage s i l o are vented t o a separate baghouse.

Design and operating parameters for the baghouses tested a t the Richmond plant are given i n Table 12. Normal replacement frequencies and most recent replacement dates for bags in the dus t collectors tested are shown i n Table u. 3.4 Process Conditions During Testinq

operations were operating a t representative, steady-state conditions d u r i n g the tes t ing, various process parameters were monitored.

In order t o ensure t h a t the calciner and the transfer and storage

All processes operated normally d u r i n g the emission testing.' The operating conditions of each of the processes i s discussed separately in the fo l lowing sections.

Direct Contact Calciner Dur ing the emission testing of the d i rec t contact calciner, o r

Calcidyne u n i t , the calciner was operated a t ful l design capacity, producing 7.0 tons per hour of calcined gypsum or stucco. b u r n i n g natural gas d u r i n g the tes ts .

stucco dust temperatures and fuel usage rates, were monitored d u r i n g the testing. steady s t a t e conditions d u r i n g a l l of the out le t t e s t runs. f i r s t baghouse i n l e t t e s t , the temperature of the process u n i t increased slightly. The baghouse out le t t e s t t h a t was r u n simultaneously w i t h t h i s f i r s t i n l e t t e s t was discarded because the f i l t e r was improperly inserted i n t o tiit. fi'itrr hoider. constant a t 1.3 inches of water.

The u n i t was \ d

Various process parameters, including in l e t and out le t gas temperatures,

The data show t h a t the process was r u n n i n g under representative

YL

During the

However, this s l igh t temperature variation i s n o t significant.

Tile baghouse pressure arop a u r i n g a i i resr runs was

-21-

c c

0 3 3

0 0

I 0 n

I

TABLE 14

L BAG REPLACEMENT SCHEDULES

Process U n i t Last Date of Normal Replacement Name Bag Replacement Frequency

(Months )

Direct Contact Calciner Early May 1980 4- 6

Stucco S i lo July 1 2 , 1980 1 2

-23-

Stucco Storaqe Silo The stucco sto,rage baghouse and si lo were operated normally d u r i n g

Stucco Transfer The stucco transfer sys tem was operating normally d u r i n g the testing.

the testing.

The system tested was transferring stucco from three calciners t o the stucco cilo. emissions were vented to a fabric f i l t e r baghouse.

The bucket elevator and screw conveyor tested for vis ible

4. U 'I'ES'I'lNti LUCA-

4 . 1 Sampling Locat ions

P a r t i c u l a t e t e s t i n g w a s conducted a t t h e baghouse i n l e t and o u t l e t . The i n l e t d u c t t o ' t h e baghouse i s 1 2 . 5 i n c h e s I D .

Upstream and downstream d i s tu rbances are g r e a t e r than 2 and 8 duc t d iameters , r e s p e c t i v e l y , away from t h e t es t p o r t s , so only 1 2 sampling p o i n t s were r e q u i r e d (F igure 4 . 1 ) p e r EPA Method 1 (Sample and Veloc i ty Traverses f o r S t a t i o n a r y Sources) . Each p o i n t w a s sampled f o r 5 m i n u t e s g iv ing a t o t a l t es t time of 1 hour.

The o u t l e t d u c t from t h e baghouse is a l so 1 2 . 5 inches I D . The t es t p o r t s are loca ted > 8 duc t d iameters from a downstream d i s tu rbance and r 2 duc t d iameters from t h e duc t e x i t t o t h e atmosphere. Twelve sampling p o i n t s w e r e used as r equ i r ed by EPA Method 1. For T e s t 1 each p o i n t was sampled f o r 6 minutes, t h e t es t time was increased t o 8 minutes p e r p o i n t f o r T e s t s 2 and 3 i n o rde r t o i n c r e a s e t h e gas sample volume. (F igure 4 . 2 )

i -25-

i- w

.w

I- C/) w I-

1 -

i

-1

T

o-p-.

z c

c

P

2

N

0 x

0

4 . 2 Emission Observation Locat ions

Ca lc ine r Baghouse Ou t l e t

A c e r t i f i e d observer conducted v i s i b l e emissions tests per EPA Method 9 (Visua l Determination of the Opacity of Emissions from S ta t iona ry Sources ) . The tests were conducted dur ing t h e p a r t i c u l a t e tes t runs. Readings w e r e taken beyond t h e a t t ached steam plume, when it ex i s t ed . The obse rve r ' s l o c a t i o n is shown i n F igu re 4.3.

S torage Bin Area

Three hours of Method 9 t e s t i n g w a s conducted by a c e r t i f i e d observer on emissions from t h e s tucco s i l o .

Three hours of obse rva t ions were a l s o conducted i n s i d e t h e bu i ld ing a t a conveyor. The obse rve r s ' l o c a t i o n s f o r t e s t i n g are shown i n F igu res 4.4 and 4 . 5 .

5.0 SAMPLING AND ANALYTICAL PROCEDURES

5 . 1 Sampling Apparatus

Nozzle

The nozz le , of appropr i a t e d iameter , w a s c a l i b r a t e d according t o procedures o u t l i n e d i n EPA Method 5. The button-hook nozzle

was made of 316 s t a i n l e s s steel.

Probe

The l i n e r f o r t h e sample probe was made of 316 s t a i n l e s s steel. A hea t ing system, capable of main ta in ing a gas temperature of 2 4 8 - + 2S°F a t t h e e x i t end, was b u i l t . i n t o t h e probe. thermocouple, used t o monitor gas temperatures , was a t t ached t o t h e probe. A p r e c a l i b r a t e d Type S p i t o t t ube was a t t ached t o t h e probe t o a l low cons tan t monitoring of t h e stack gas v e l o c i t y . The p i t o t tube was cons t ruc t ed i n accordance wi th EPA Method 2 .

A

ci I .

-28-

I

POSIT10 CF OBSERVER - BAG

figure 4.3

E I ‘ s “ I

L-l

JTLET

....

\

POSITION OF OBSERVER - STUCCO SILO

,figure 4.4

Conveyor enclosed

In ductwork

hood

emissions possible through top edge

ObeeNer on stairs

POSITION OF OBSERVER - CONVEYOR

figure 4.5 L i

F i l t e r Holder

A t a r e d f i b e r g l a s s f i l t e r w a s encased i n a b o r o s i l i c a t e g l a s s f i l t e r ho lder . A g l a s s f r i t supported t h e f i l t e r . A s i l i c o n e rubber gaske t was.used t o provide a p o s i t i v e s e a l a g a i n s t leakage from around t h e f i l t e r . The f i l t e r ho lder w a s conta ined i n a heated box capable of main ta in ing a temperature of 2 4 8 - + 25OF. A thermocouple, a t t ached t o a pyrometer was used t o monitor t h e temperature i n s i d e t h e sample box.

Impinger T r a i n

The t r a i n cons i s t ed of a series of fou r impingers connected wi th l eak - f r ee ground g l a s s f i t t i n g s . The f i r s t , t h i r d and f o u r t h impingers were of t h e Greenburg-Smith des ign , modified by r ep lac ing t h e t i p wi th 1 . 3 cm I D g l a s s tube . The tube extends t o approximately 1 . 3 c m from t h e bottom of t h e f l a s k . The second impinger was of t h e Greenburg-Smith design wi th t h e s tandard t i p . The impinger t r a i n w a s contained i n an ice ba th t o coo l t h e sample gas stream. A d i a l type thermometer, capable of measuring temperatures t o wi th in 2'F was placed a t t h e o u t l e t of t h e f o u r t h impinger f o r monitoring purposes.

Metering System

I

A R.A.C. Tra in stacksamplr' w a s used f o r t h e metering system'. The system c o n s i s t s of t h e fol lowing:

e Cal ib ra t ed o r i f i c e e V e r t i c a l , i n c l i n e d , dua l manometer ,e Dry gas meter (capable of measuring volume wi th in 2

per cent) e Vacuum gauge e Leak-free pump 0 Thermometers (capable of measuring temperatures

wi th in 5.4'F) e Elec t r i ca l c o n t r o l s f o r sampling

Research Appliance Company, Gibsonia , PA

-32-

- The o r i f i c e and dry gas m e t e r w e r e c a l i b r a t e d i n accordance 2

i with APTD-0576 .

i

5 . 2 Pre l iminary Measurements

Gas v e l o c i t y and temperature were measured a t each sampling 1 o c a t i o n . i n accordance wi th g u i d e l i n e s o u t l i n e d i n EPA Method 2

(Determination of S tack G a s Ve loc i ty and Volumetric Flow Ra te ) .

The v e l o c i t y p re s su re was measured on an i n c l i n e d , dua l mano- meter and t h e temperature w a s measured on a pyrometer. Measure- ments were recorded a t each t r a v e r s e po in t .

A n i t i t i a l de te rmina t ion of t h e moi s tu re i n t h e gas a t each loca t ion w a s a l s o made. The moi s tu re t r a i n w a s s imilar t o t h e p a r t i c u l a t e sampling t r a i n , excep t t h a t a f i l t e r w a s no t used. The volume of water c o l l e c t e d a f t e r sampling a t a cons t an t r a t e f o r 2 0 minutes was measured.

5.3 P a r t i c u l a t e Sampling

The p a r t i c u l a t e emissions from t h e baghouse were determined i n accordance with g u i d e l i n e s o u t l i n e d i n EPA Method 5 (Determina- t i o n of P a r t i c u l a t e Emissions from S ta t iona ry Sources ) .

S amp1 ing

The sampling t r a i n a t each tes t l o c a t i o n cons i s t ed of t h e nozzle , probe, f i l t e r ho lder , impinger t r a i n and metering - system. The sampling t r a i n is shown schemat ica l ly i n F igu re 5.1. A l l connect ions were leak- f ree .

The nozz le s i z e w a s determined us ing d a t a obta ined from t h e pre l iminary measurements. The f i r s t and second impingers were each i n i t i a l l y f i l l e d w i t h 1 0 0 m l of d i s t i l l e d water . The t h i r d impinger was l e f t empty. The f o u r t h impinger w a s f i l l e d wi th 300 g of d ry , i n d i c a t i n g type s i l i c a g e l .

Rom, J .J . , Maintenance, C a l i b r a t i o n , and Operation of Iso- k i n e t i c Source Sampling Equipment, Publ. No. APTD-0576, Of f i ce Of A i r Programs, EPA, Research Tr i ang le Park, NC 1 9 7 2 .

- 7 7 -

. .

W c a - f m .z

w V -

Lc w I- s 0 Lc > R

m

0 m

L I-

During each tes t , t h e fo l lowing d a t a w e r e recorded a t each

t r a v e r s e point :

Po in t des igna t ion Clock time (24-hour c lock ) Dry gas meter r ead ing (V f t 3 ) m' Veloc i ty p re s su re (Ap, i n . H 2 0 ) Desired p res su re drop ac ross o r i f i c e ( A H , i n . H 2 0 ) Actual p re s su re drop a c r o s s o r i f i c e ( A H , i n . H Z O )

Stack temperature (Ts, F) Dry gas meter temperature a t i n l e t and o u t l e t (T,, F) Vacuum gauge reading ( in . Hg)

0 Sample box temperature ( F) Dry gas temperature a t e x i t of l a s t impinger ( F)

0

0

0

The r e l a t i o n s h i p of t h e Ap read ing w i t h t h e AH reading i s a func t ion of t h e fo l lowing va r i ab le s :

a O r i f i c e c a l i b r a t i o n f a c t o r a Gas meter temperature a .Moisture con ten t of f l u e gas

Rat io of f l u e gas p re s su re t o barometr ic p re s su re a Stack temperature

Sampling nozzle diamete,r

A nomograph w a s used t o c o r r e l a t e a l l of t h e above v a r i a b l e s such t h a t a d i r e c t r e l a t i o n s h i p between Ap and AH could be determined by t h e t es t t echn ic i an and i s o k i n e t i c cond i t ions

could be maintained. I n i t i a l and f i n a l leak checks were per- formed on each sampling t r a i n p r i o r t o and upon completion of each tes t t o confirm t h e e x i s t e n c e of a l eak - f r ee system ( leakage r a t e s d i d no t exceed 0 . 0 2 cfm per EPA s t a n d a r d s ) . A l l

measurements were recorded on t h e d a t a shee t s .

Sampling a t t h e i n l e t l o c a t i o n w a s complicated by t h e extremely high p a r t i c u l a t e concen t r a t ion i n t h e gas stream. The f i l t e r s qu ick ly became laden wi th p a r t i c u l a t e matter. A t l e a s t t w o f i l t e r s were used f o r each t e s t and t h e probe was f r equen t ly

-35-

.-

removed from t h e s t ack and 'shaken t o d i s lodge t h e accumulated dust-cake from t h e f i l t e r . Although t h e sampling time was only 1 hour, t h e . i n l e t tests took approximately 2 hours t o complete.

Some t echn ica l problems caused t h e f i r s t (7/15/80) o u t l e t t es t run t o be voided. Three t es t runs were made on t h e fol lowing day. Only two o u t l e t t es t runs co inc ide .wi th i n l e t tests.

Sample Recovery

Upon completion of each test , t h e sampling t r a i n s w e r e d i s - assembled t o permi t sample recovery. The samples were recovered i n t h e fol lowing manner:

F i l t e r - t h e f i l t e r w a s removed from t h e f i l t e r ho lder and placed i n i t s o r i g i n a l con ta ine r .

Front-half Acetone - t h e nozz le , probe and f r o n t ha l f of t h e f i l t e r ho lder were r in sed wi th acetone t h r e e times. The wash was c o l l e c t e d i n a g l a s s sample j a r which had a t e f l o n - l i n e d l i d .

- t h e s i l i c a g e l was r e tu rned t o i t s

- a sample of ace tone from t h e f i e l d o r i g i n a l con ta ine r .

supply was c o l l e c t e d i n a g l a s s j a r , which had a t e f lon - l ined l i d .

S i l i ca G e l

Acetone Blank

I...

Each sample con ta ine r w a s l abe led with t h e d a t e , con ten t s and tes t number and sea l ed wi th t ape . The volume of water i n t h e f i r s t t h r e e impingers was measured and recorded on t h e d a t a shee t s . The water w a s d i sca rded .

Sample Analys is

Each sample w a s analyzed i n t h e fol lowing manner:

-36-

F i l t e r - t h e f i l t e r was removed from i t s sea l ed con ta ine r and placed on a t a r e d watch g l a s s . The f i l t e r and watch g l a s s were d e s s i c a t e d over anhydrous C a S 0 4 f o r 24 hours and weighed t o a cons t an t weight. The weight w a s recorded t o t h e n e a r e s t 0 . 0 1 m g .

a t a r e d beaker. The acetone w a s evaporated a t ambient temperature and p res su re . The beaker was des s i ca t ed f o r 2 4 hours and weighed t o a cons t an t weight. The weight w a s recorded t o t h e n e a r e s t 0 . 0 1 mg.

and t h e weight was recorded t o t h e n e a r e s t 0 . 1 gram.

Front-half Acetone - The ace tone washings were t r a n s f e r r e d t o

S i l i c a G e l - The s i l i c a g e l w a s weighed on a beam balance

Acetone Blank - The ace tone blank w a s t r a n s f e r r e d t o a t a r e d beaker . The ace tone was evaporated a t ambient temperature and p res su re . The beaker was des s i ca t ed f o r 2 4 hours and weighed t o a cons t an t weight. The weight w a s recorded t o t h e n e a r e s t 0 . 0 1 mg. This weight w a s sub t r ac t ed from t h e f i n a l weight of t h e f ron t -ha l f ace tone r e s idue t o ob ta in t h e n e t weight of p a r t i c u l a t e i n t h e f r o n t h a l f wash.

5 .4 Gas Composition

The f l u e gas was analyzed f o r O 2 and C 0 2 con ten t w i t h a F y r i t e ana lyzer .

5.5 P a r t i c l e S i z e D i s t r i b u t i o n

The p a r t i c l e s i z e d i s t r i b u t i o n samples were c o l l e c t e d us ing an Andersen Cascade Impactor. The impactor aerodynamically c l a s s i f i e s p a r t i c l e s i n t o mul t ip l e s i z e ranges . I t c o n s i s t s of e i g h t s t a g e s

-37-

and a back-up f i l t e r (F igure 5 . 2 ) . Each s t a g e c o n s i s t s of a conf igu ra t ion of o r i f i c e s of s p e c i f i c d iameters above a c o l l e c t i o n p l a t e . Tared g l a s s f i b e r s u b s t r a t e s were used on each s t a g e a s c o l l e c t i o n media.

D i f f e r e n t s i zed p a r t i c l e s are impacted on each s t a g e correspond- ing t o t h e s i z e of t h e o r i f i c e s on t h e p l a t e above t h e c o l l e c t i o n s u b s t r a t e s . The range of p a r t i c l e s i z e s r e t a i n e d on each substrate var ies according t o t h e v e l o c i t y of t h e gas (as determined by t h e sample r a t e ) , t h e gas v i s c o s i t y and t h e p a r t i c l e d e n s i t y . S ince t h e o r i f i c e s are arranged i n descending diameters , t h e gas v e l o c i t y i n c r e a s e s and t h e p a r t i c l e s i z e c o l l e c t e d on each s t a g e dec reases .

S amplinq

The sampling appara tus cons i s t ed of an Andersen impactor, e i g h t pre- ta red s u b s t r a t e s and a pre- ta red backup f i l t e r , nozzle , d ry ing tube , vacuum pump, d ry gas meter, c a l i b r a t e d o r i f i c e and manometer (F igure 5.3) . The sample t r a i n w a s checked f o r l eaks a t t h e completion of each sample run. Any leak r a t e above 0 . 0 2 cfm w a s considered unacceptable .

Using d a t a obta ined from t h e v e l o c i t y t r a v e r s e , a sampling r a t e (AH) w a s ca l cu la t ed . (Refer t o Appendix 6 . 2 f o r c a l c u l a t i o n s ) . During each tes t t h e fo l lowing d a t a were recorded:

Po in t des igna t ion Clock time (24-hour clock) Dry gas meter readings (Vm, f t ” ) Actual p re s su re drop a c r o s s o r i f i c e ( A H , i n H 2 0 )

Dry gas meter temperatures (Tm, F) P r e s s u r e drop, i n s t a c k ( i n . Hg) Vacuum ( i n . Hg)

0

-38-

ANDERSEN STACK SAMPLER

i

SPACERS

NOZZLE I;

CORE

1 -

ES-095

Figure 5.2

-3 9-

a K c

.J

i4 a z W v) K w 0 z c

m I 0 w I

c D. 0 I

rn L;!

Sample Recovery

The Andersen impactor was disconnected from t h e probe and brought t o t h e Gold Bond Laboratory f o r clean-up. S t a r t i n g with s t a g e 1, t h e f i b e r g l a s s s u b s t r a t e s were removed from t h e impactor and r e tu rned t o t h e i r o r i g i n a l con ta ine r s . There were a t o t a l of 8 s u b s t r a t e s and one backup f i l t e r f o r each sample.

Sample Analysis

The f i b e r g l a s s s u b s t r a t e s and t h e backup f i l t e r s were dess i ca t ed and weighed t o a cons t an t weight. The n e t weight ga in was recorded t o t h e nearest 0 . 0 1 mg.

. .

- I -41- . .

Prepared by:

Reviewed by:

Approved by:

YRC PROJECT NO. 01-9517-29

. P r o j e c t S c i e n t i s t

P rg jec t Manager Emiss ions Measurement Dept.

6.0 APPENDICES

6 . 1 Computer Data P r i n t o u t s

6 . 1 . 1 P a r t i c u l a t e T e s t s - Baghouse I n l e t

.rile I4 I I h C!4 : 9 5 t 7-- 29- ........ . . . . . . . . ...... .- . ._ .. ~. Y 0 H K R F.S F: A L, C 14 Cr) C P I I R A T I U rU O V F RFSEAkCH D R I V F , STauF f lPD, CONNECTICUT 0 6 9 0 6 -

-~ . . . . . - ...... . . C I , T F F J T : k:PA-GI~lLD H o N r ) L

D L A IN 'P I INTT TFS lF I ) : C:I,C[MFk*l - R A G H O U S E INLET

LI IC A T I 0 Y : H T C H M.Il P: P , C P

- . . ~ . . -. .... ........................ - ... ...... ........ __- . . .

P A H T l C l l t A T l ? SUMMARY Ti4 ENGLJSH IlPlITS

DFSCRJPTCON I I N I T S 1 2 3 AVERAGE , . . . . . . . . . . . ............. ........

G E V F R A I , i ) A ' r A

RARnMETRlC Pi71.2SSIIRE 1V.HG 3 0 . o 1 .... 3Q.01- ... 30.01 . . . . . . . . .......

D4TE I!F R I I N JllL-l.5,HO JIIL 1 6 , 8 0 J l l L 16,HO

ST4CK P ~ E S S I I H K , P R S . 1hi.HG 29.72 29 .72 29 .72 SrACK 4 R E 4 SO. F T 0. li 5 U . H 5

. . . . .

cas ~ & T A A V C STACK G A S VELl lCTTY FPS 7?.4H4 7 2 . 7 1 3 _ . . 7.2 .Y 7 7 1.2 ..7 2 s .- _. . A V G STACK ' T E M P K R A l l ~ l R f 7 DE(;.F' 3 o 0 . 7 297.7 305.8 301.3 ACTIIAI, S T A C K FILC;~,HATE: , ~ r ~ d 37175. 3717. 3 7 3 1 . 3 7 1 8 .

73 .4P 0 .474

7.0 1 1 .n

0.0 a2 .0 5 7 . 6 -

.....

24.33 23.7H 0.548. 0 . 5 g.0

7.n 7.0 7.0 ... 11 .... 0 . .... 1 1 - 0 . . . . . .! !.* 0. . -

0 . 0 0.0 0 . 11 82.0 8 2 . 0 82.0 4 5 .,2. . . . . so. 0 4 '9. 3 ....... .-

674 .0 73n.n

PA H T 1 C I 1 I, A 'r F: EM I S S T I l N 5

o . on n II 0 . n 9 0 n o o . o n (J o o I) . o 1.1 II Q u P o u r i i i s P ~ . H HPIUR n.no 0 . 0 0 0.00 a.nn

._ (;PATPIS Pk:H A r k ' . . . . . . . . . . . . . . . . . . . . ... ........ ....

. . . . . . . . .

- .Jr)fl NUMhk:R: q 5 1 7 - 2 9

_________. . . . . 1 OR i( R FSF: ~. A h'C tl CnR . Pi3R 4 T I [IN .......... ..... .

O N F R E S F A R C H ' O C ~ I V F , STP,MFIIRD, C~NN~CTICIJT ob906 -

L ~. . . . . . . . . . . CLIFF!' I : EPA-GULD RDbin PLANT I 8 [ I C A T l 0 t u : WICH*flNn,CA 1lNTT TFS'I'FU: CAi,CTbiFHSl - A A C , H I l ( I S I . : 1 N LCT

. . . . . . . __

P A R T l C l l L A T C SlJVqARY I N METRIC U N I T S

. . . . . . . . . . . . . . . . . . . . . . .- . . . . . . . . . . . . . . . . . . - .. -. DFSCRJPTIOQ 1lNIT.S 1. 2 3 4 V E H AGE

. . . . . . . . . . . . . . . . . . . . . . ....... - . . . . . . . . . .~. GENFRPI, D A T A O A T E OF HUN JUL 1 5 , ~ ~ JIIL i f i , R n J U I , 16.~0

STACK P P E S S l J e E , AKS. :qM.HG 7 5 4 . 7 R - . .754;71i 7 5 4 . 7 q--- - STACK \REA r:! 0 , (I 7 5) (i . 1) 7 Y 0 . 0 7 9

6 o . n 6o.n NFT T I M 5 O F e i l b 6 n . o P E R ~ ~ w r I ~ O K I t; E T I c -- 1 n 9 .7---- -- i o i . 3 1 IJ 8 - 3 i o h . 4 G 4 S DPTA AVG STACK C A S V E L l l C l T Y V / S 22.0') 3 2 3 . 1 6 3 4 V C SThCK T E M P ~ H A T I J R E 1IEG.C 1 4 0 . 1 1 147.5 1 5 2 . 1 - I 4 Y . b ACTllAl, S T A C K FI,UIUi?PTF AK.3/!4 1.05. 1(!5. l l j b . 105.

3t7. 3 7 . . . . . . 23;56.. ~ . . . . . . STY F I . I I * ~ R ~ T E , L J H Y ,STn n l \ r h i 3 / M 3 6 . 4 0 . . ~ O [ . I . T I I I , P ~ . i ~ r - ~ r y STK- (;JS 29.36 29;5F, MClI,ECiI1,4); nT-STK GAS 23.4H 2 4 . 3 3 2 3 . 7 9 t4nL.E FRAC' I1 i . l i u I ) H Y C A S 0 . 4 7 4 0.548 0.500 G A S A~!AI,YSIS ( D P Y PERcrb. r HASIS)

. . . . . . . . . . . . 7 6 2 . 2 5 _ . . R4 l j f lMFTRIC PRCSSl!PF M M . H G 7 6 2 . 2 5 762.25

...... . . . .... ... ~ _- ~. -. ._ .-

. 2 2 . 2 4 3 .~ 2 2 . 1 6 7 - .........

. .

. . . . . . . . . .

C P P W ~ J otuxTnE 7 . 0 7 . 0 7 . 0 7 . 0 1 1 . 0 1 1 .o 1 1 . 0 1 1 . 0 n x y c K r 4 .

C4PaON MUi4CiXTnF 0.0 0.0 0 . 0 0. 0~ N .I T H 0 G E N 82.0 H2.0 R2.O H2.0

S O . 0 49.3 InrlIs'ruHc M Y vo i , 52.6

............ . . . . . . . . . . . .- ........ . . . . .......

. . 4 5 . 2 . . . . . . . . . . . . . . . . . . . . . . . . . SAIJPI,E. C t i L LKC'I' 1 I i h I? 4 T A Trl'PAL H2U COLI,ECTFP . M I , 7 ~ 0 . 0 h25.0 7 3 0 . 0

0 ; 9 d v o i , 1.120 J A F I ) ~ - S T D cotin ~ ! 4 3 1 .I15 V O I , n R y G A S - M C T E P CrJNn I I Y ~ 1 . 0 1 1.08 1 . t ih vni, D R Y C;as-s.rD c t i u n P N V ~ 0.95 1.01 0 .93 A V G GAS HETER TFMP @EG.C 4 4 . 2 4 1 . 1 46.3

PARTICIILA'I 'F: WEIGHT I I A T 4

. . . . . . . . . . ............. . .......... 0 . h 4 -~

4UG O W T F Pk!ES I t i?VP MM.V711 3 3 . 7 6 1 3 5 . 2 4 2 3 5 . 0 8 4

0 . 0 0 - n .no o.on 0.00 . . . - ..... .- . ... .... .. NET WElCt iT P A H T I A i s W G N E T d i i r ~ i + r r i j , r A i - M G 4 6 2 3 7 . 2 0 4 9 2 7 9.90 5 1 4 2 3 . bo-..... 4HOa.0.57 ...

111 . 0 0 0.00 'i . 0 0 0.00 ........ - . - ............. .... -. .......... ....... n. nti 0 . 0 0 0 . 9 0

S T A k T 0.0 4 - 1 7 .5 1 5 . 0 7 7.5

3 1 7 . 5 3 1 5 . 0 4 1 7 . 5

5 22.5 5 25.0

7 10.0

n 2 0 . 0

332 .235 3 34 .10 1 - 335.h~o 3 37.nrln 33H.550 3 3 9 . 9 4 0 3 4 1 . 2 s n 3 4 2 . 8 4 t 344.440 345.8RO 3 4 7 . 3 ~ 0

I . n n o n. ? s o n . q n n n . 9 5 T 0 . R 5 0 0.@5c, 0.530 n . a n n 0 .770 0 , 7 0 0

. .

I . h n n 1.SOn I . 3 n o 1 :-4 5 0-

I . 3 5 0 1.300 1 .300 I .200 1 . t n d

.. .

1.350

OR. 9 4 . l n h . 1 0 6 .

i t n . i n k . 1 1 7 . i n R . 1 1 4 . 1 o R . 1 7 0 . 1 1 0 . -122. 1 1 7

- -0 ; 7 5-5

0.255 330 .

0.255 330 .

3 4 5 . 0.255 330.

0 .255 330.

0 . 2 5 5 340 . 0 . 2 5 5 3 4 9 . 0 . 2 5 5 3 3 s . n.2ss 335 . n..3s.s----

2 6 0 .

.. . . .. ._ . .

~~ . 3 n . s d l . i O 9

7 8 . 6 9 4 112.2 7 2 . 3 9 9 l O o . 8 73.394--- 109 .4 71 .677 103.7 7 5 . 0 4 ~ i n o . 4 7 3 . 7 6 0 111.9 72 .627 122.Y

. - .

.. . . . -. . .. - - ..

7 1 . 2 5 3 112.4 6.3.74H - 1 1 3 . 5

u- 1 37.5 3 s n . 2 4 0 i . n n n I ' 35 .n z59.t,70 1.050 2 37.5 3 6 1 . 3 ~ ~ 0 .9sn 7 4n.o 3 0 2 . ~ 5 1 n.94n 3 4 2 . 5 3 a 4 . 5 0 0 0 . ~ 2 0 3 .ns.u 365 .905 0 . ~ 1 0 0 47 .5 357 .450 0 .760

. ~... ... _ _ . . __ .- . .~ . .. .

~ . .. . .. . . . ...... . .... . ..- .. . _ _

. .. ~ --

- - - -. .- . -~ - .. ... ... . . . . ..

- . .. ... . . . . ~ . .. .

. . . -. . . . . . . . . . . . . ............ -. ....... ... ....... STAHT 0.0 3 7 5 . 6 4 5 2 . 5 3 f 7 . 0 0 0 1.100 1.751) Rh. RE. 0.155 335 . # 3 . h h 9 RO.6

2 3 1 7 . 5 383 .150 3 i 5 . n 3 8 4 . 4 9 7

4 7 0 . 0 3 ~ 7 . ~ 1 5

5 2 5 . 0 3 9 I - 4 0 0

4 1 7 . 5 3db.7nO

5 22.5 389 .77a

6 7 7 . 5 393.(1n7 6 30.6 394.474 START 30.0 3 9 4 . 4 7 4

0 8 . 1 1 . 13 . IS. 15. is . 1 R . .. 2 2 * ~ .

0.255 335. 0.255.. 340.. n.2ss 3 4 0 . n . 2 5 5 34li.

,O,SS .. . _ . ? I . ? . 0 .255 310 . 0.755 I b O . r1 .255 . . . 15.0.

nh. 0.255 335. ( ! I . 0 . 1 5 5 3.35. 08. 0 . 2 5 5 3 3 s . o e . 0 . 2 5 5 335.

7 7 . 7 5 s 77 .999 7 3 . 7 ii 0 71.517

.~ 7 1 . Y N $ ~ ~ ~ - 71.956 6 5 . 6 0 2 5 4 . 1 7 U ~ .

1 7 . 3 4 5 - 77. 345 73.980 7 3.98 0

ne . o.;!s5 - 3 3 5 . . 7 3 . 9 4 0 118. fI.?55 3 3 5 . 73.9dlJ

8e .2 05.u YS.8 - - 14.0 10 .9 2R .I 0 6 . 4 96.1 il 1 . 0 -

0 4 . 4 04.0 . 0 3 . 6

. . . . . . . . . . . . . . . . . . . _ _ . ............

. . . . . . . ... ..........

.. __ . . . . . . . - . - ..... .......

.................. __ .......... - ... - . -. ... . . . . . . . . . . . . . .

.. . . . _ _ ...... ~- . . . . - - . .

1 2-

1 . 5 0 0 1 . 4 5 0 1 . 4 0 0 1 .300 1 .4nn

I .n59 i . n 5 0

1 .hnn i.+,nn t .Jon- 1.400 1 .os0

1.400

1 .son t .4i)0

1 . 3 0 0

n.950 1 .400

1 . 4 0 9

1 . 2 0 0

12. 108. r i .255 1 4 . 1 0 9 . n . 2 s s 2 0 . 1'10. r j . 2 5 ~ 20. 110. 0.255 2 0 . ~- 11. 0 .755 2 0 . 110. n.2ss

.

22. 112. 0.25s 7 2 . 1 1 2 . 0 .255 . . . . . . .

,340. 3 4 0 . 3 4 0 . ? A n .

'.3-lJ0.- 1 7 0 .

3on.

170: . . . . . .

1 2 0 . 1 1 4 . 0 . 2 5 5 3 4 0 . 1 2 0 . 1 1 4 . 0 . 7 5 s 3 4 0 . n. i 5 5 ~ . . li2:--11h.- . . 3 4 0 . 1 2 6 . 1 1 6 . 0 .255 3 4 0 .

130. 120. n . 2 s s 3 4 n . 3 4 0 . 1 3 0 . 1 2 0 . 0 . 2 5 5 -.

l 3 n . 12'0: 0 . 2 5 s - j o o . 1 3 0 . 1 2 0 . 0 .255 3 0 0 . 1 3 0 . 122. 0 .255 ~ R O . 1 3 0 . 1 2 2 . 0 . 2 5 5 I Y O .

130. 1 1 8 . .. 0.255 3 4 0 . 1 3 0 . 1 l H . 0 . 2 S S - . - 3 4 0 .

. _.

STaCK v FI!

(FPS 1

-H 0'. 9 3 H 80.93Y 8 0 . 9 3 U 8 9 . 9 3 8 7 8 . 4 7 3 7 6 . 7 4 5 7 5 . 0 5 9 7 2 . 3 9 4 7 3 . 1 5 9

S7.90H

......

7 ~ i ~ i 5 ~ 0

5 7 . 9 0 ~

t l 0 . Y 3 R 8 d . 9 :3 H 7 5 . 9 5 9 7 5 . 0 5 9 6 4 . 7 5 1 6 1 . 6 4 1 7 4 . 6 2 2 7 4 . 6 2 2 72;3G3 7 5 . 6 h 8 6 6 . 7 4 4 h 3 . 1 1 1

. . . . . . . . - .. . . . . . . . . . . ._

. . . . . . . ......

. . . . . . . . . j ( i2.0 l ( J 6 . 2 1 1 3.0

99.4 69.5

4Q.7 9 3 . 6 17.5 0 5. : 3 O7 .O 99.5

l h . 3

- .. . -

n 7 * 5 . . .

. . . . . .

- - ....

10.0 3 7 .9

.

10.11 104.5 l l 0 . R

-. -.

103.4 1 no.. i . 90.1

.......... .-

............ . .-

. . . . . . . . . . . . . . . . . . ---. . .-

- ......... -. .... .- . .............

... . . . . . . . . . . . .

.\. ,

6.1.2 Particulate Tests - Baghouse Outlet

. . . . . . . . . . . . . . . . ........ .. - ..... - . ..... ..

.. . . . . .- ........ ....... . -. ................ ' PA.HTlCUI,ATF S l l M M P R V 1 b! E Q G L I S h l l N 1 T S

-. ~ ~ .. ... .

DFSCR I PT I O N I 1 N T T S t 2 3 V FIR AGE

. . . . . . . . . . . . . . . . . . .... .......

-. . . . . . . . . . . _. ..... ......... ....... - . . . 7 . 0 7 . n 7 . 0 7 . n

11.0 1 1 . 0 1 l . r ) 1 1 .I, 0.0 . . . . . 9.0.

4h.2 A7.6

9.37.0 1129.6 4 4 . 1 8 s3.54 5 1 .q.4 6 9 - 2 4 51 .47 sjri,q2

H 2 . n ~ R2.0

.. -. ... -. __ .- -~

7 0 . 1 a5 .4

n . n n . n . . . 8 2 . 0 RE. I l 4q .3 47.7

-. -- .-.. .- . - ... . 1 1 0 2 . 8

52 .27

5 3 - 7 3 87.1

55 .15 . . . . . . .

0 .00 0 .00 0.00 n . t i n lS.6-H . . . . 1 5 ..e2 ..... 3 1. .. Q 5 3 ? . 5.6

S T ~ P T 0.0 A-I 3.0 7 6.0 3 0 . 0 4 1 7 . 0 5 15.0 h 1 a . o 7 71 .n 5\ 7 4 . 0

i n 3n.n

1 7 3h.n

9 77.0

1 1 3 3 . 0

S T A R T R - 1 2 3 n 5

7 9 cr

I t 1 7

6 ..

t o

74. 6 4 . 1 6 . h 5 . 7u. hb. H 2 . hi(. Q 3 . ha. . 8 5 . 7 0 . R H . 70 . R 9 . 70. # } I . 7 0 . an. 7 2 .

.~

0.259 3 3 0 . 0.259 .. 3 2 5 . n.2siR 3 3 n . n.2sr) 3 3 0 . 0.259 - 3 3 3 . 0 . 2 5 Q 3 3 0 . 0.259 331-1. n.259 325.

.... - .........

6 . 2 5 9 - - - 3 3 n . 0 . 2 5 s 33n.

. _. . . . . . -. .. S? 4cU % I

V E L -- ( F P S 1 --

. . . . . - ........ - ...

. 72.3

109.6

11)9.3

-. . 1 0 9 . 4 .1 1 0 .~0

,110 .0

....

IO?,. 7

107.U lnH.3

,I 11.7

..... - ...... -. ..

. . . . . . . . . . ... .. . . . . . . . - . . . . . . . . . . . . . . . . . -

.. . . . . . . . . . . - . . . . - .... .__ .- .... -. --

.. -. . .......... - ....... . . . . . . -. .- . .

- ............... - ..... - - . . . - - ... ........

. . . . . . . . . _. .... . . . . . -. - ___.

3 12.0 4 l h . 0 5 20. (I h 2 4 . 0 7 7u.o

9 3 6 . 0 9 37.0

i n 40.0

7 4 2 . 7 0 5 7 4 5 . 2 7 5 7 1 7 . 9 5 5 7 50.67s 7 5 3.2c15 7 55.7 Q 0

7 h 0 . 7 7 0 7 5 a . 7 9 5

1 I

.son 7 4 . 7 4 . 0 .249 330. 7 7 . 7 7 7 1 3 5 . 0

.I550 92. 7 2 . 0.21u ~ , 330 . , .9 . l .57.3 ~ 1 0 A . S ,

. ~ n n 8 4 . 7 4 . n . 2 1 9 3 3 0 . ~ 5 . 2 0 1 1'18.1

.Ron qn. 74. n . 2 1 9 3 3 0 . ~ 5 . 2 0 1 i n 7 . 4

.6 so ... sn . .-7 4. n .2.49 . . . . 3 30 .. ... 5 i ... 57 3- .. 1 nq . -* .....

.65n o s . 77. n . 7 4 u 3 3 0 . 8 1 . 5 7 3 107.7

.5sn qfi. 7 ~ . 0 .249 3 3 0 . 7 a . 6 9 3 i n 7 . h

....

....... . . . . . - .. START A Q . O 765 .4R5 . ~

R - 1 52.0 7 6 7 - 9 4 0 i . i n n 1.651-1 R P . R O . 0 . 2 4 9 330. 7 Sh.0 7 7 0 . 5 3 0 3 6n.0 773.0RO

6 .7?.n 7 ~ 0 . ~ 3 n 7 76.11 7 ~ 3 . 2 5 0 A Hn.0 7$5.639(! 9 84-17 7 8 6 . 0 6 0

1 1 '7.U 7 9 2 . 7 3 0 1 2 Qh.!) 7Y5.0P'i

4 '64.9 7 1 5 . h 5 5 5 6R.O 7 7 6 . 7 1 5

i n Y P . 0 7 9 0 . 3 0 5

40. 80. 92. 8 1 . 0 7 . 91 . 9 V . Q2. 5 7 ... Q 2 .. 9H. H2. on. 8 3 . on. 8 3 . . 01. q 3 . O ? . 8 4 . !'.?.._ RP.

0.249 0.238 n . 2 4 ~ n.249 . . 0.249 ..

0 . 2 4 0 o.740 0.149. 0.249 0 .749 ...... rr 2 4 ~ - .

330. 3 3 n . 3 3 0 . 3 3 0 .

.. - 3 3 0 , 3 3 n . 335. 3 3 5 . 3 3 0 . 3 3 0 .

- .. 3 1n.

. . . . . . . . . . . . . . ....... -. - -

. . . . -. _ .... - - _. - .. ....... ...

. . . . . . . . . . . . . . . . . . . ... .- - -.

... ......... ................. ........... - ... ~~ . . . .

....

. . . . . . . ... ...... ... . ---

STAUT h - 1 3 3 4 5 6 7 R 9 1 \? 1 1 17 STAPT R-1 7 -3 4 5 6 7 R a

1 1 12

i n

n . I) 4 . 0 P :o

1 2 . 0 16.n z0.n 70. I) 7*.0 .3 2.13 36.0 4 0 . o

4R.O A n . 0 57.0 56.0 6O.F 6 4 . I1

4 A . i )

68.0 7 2 . 0 7 h . n

84 .0 R O . n

R R . 0 97.0 Qh.0

7 s . 0.74q 331). 7%. 0 . 2 4 9 3 5 n-.-. 7 9 . o.24q 3 3 0 . 7 ~ . (1.2440 3 3 n . 7 H . 0.29'4 3311.

. . . 9 1 . n.74a . - . . . . . 3 3 0 .

........ -

PO. 0 2 d 9 3311.

8 2 . 0 . 2 4 9 3 31). 92 . 0 . 7 4 9 330. r i 3 . 0 . 2 A Y 3 3 0 . h4. 0 . 2 6 9 3 3n. SS. 0.240 331?.

8 1 . 9 1 0 1 n 3 . 1 e 1 . 9 1 I r 102.9 d l . V l 0 1 0 1 . 9 80.Q7ti 1173.3 74.1192 1 0 3 . 7 7 3 . 0 9 8 1 0 2 . 4 7 5 . 7 1 U 1 0 3 . 2

.. - -. ..

. . .

~ ....... 7 5 . 7 1 9 1 n 2 . o 74.909 i n z . 6 -1.1 . ns o I o 2 . q 7 4 . 0 9 1 1 101 . 3 '72.425 1 f l 4 . 2

. . . . . . . . . . ~ ....

...... .......... ........ -

. . . . . . . ................. . ._._ .

.. ..... ..... ...... ... .- .

6.1.3 Particle Size Distribution Tests

. . . . . . . .......... ...

.... . . . . . . . . . . . . . . . . ....... .....

A hlDFRSFlN P A R T KCLE S I Z I N G . . . . . . . . . . . . . . . . . . . - ......... - . . . . . . . . . .

nI AHF,I.LR w F: I i: H 'r 9; PEP C I I M % r. R sc F I? *I G 31 c +, r) srAccy i u Icp i i i . i s ) ( M T L I ~ T G R A M S ) STACE <II IJPER P I A M PI.:* S T O G Y P E H S T A G E

1 > 7 . 0 5 1 5 7 . 5 1 5 8 . 5 1 7 . 0 0 2 9 7 7 + i t . * + :

? 7 - 0 5 - 4 . 3 7 7 7 . 6 4 1 0 . 2 7 4 1 . 4 9 1.229dHR . 2 8 1 2 . 5

3 4.37-2.91 3 1 . 3 7 1 I . 4 5 .31.2 2 1 . 3 P 4 7 2 h 3IQ2.1

. . . . . . . . . . . . . . .- . .-

.... - . - ............ .. . . . . . . . . . . . . . - -. . J 2.94-1. q u 1 u . '62 6 . 9 7 ' 1 9 . 5 6 n . 3 2 7 8 ~ 4 1 9 9 4 . 7

S 1 . Y 8 - 1 . 2 5 .. 17_,nR h . 3 5 1 ? . b 5 . . . 0 . 7 5 9 3 8 5 1 7 3 ~ . o

h 1.25-U.hO 1 2 . 2 6 4 . 5 5 b . 3 0 O.S4Sl) i3h ' 124'1.5

7 o.bo- i I .3s 2 . 9 5 1. .OF, I . 7 S 0 . 1 2 6 7 1 2 2 9 0 . 0 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . _. .... . . . . . . . . . . . . . .-

Y n. js-o.2n 0.79 . 0 . 2 9 ......... 0 . 6.9 0 . 0 35.1 2 4 ~ n . 3 9 . .

FT14TFP C 0 . 2 0 1 . 0 6 '0.39 0 . 3 9 o . 0 4 7 1 2 8 1 0 7 :e6

. . .~ . ............. -~ .... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. 2 . 7 2 0 ,. 0.694 . 0 . 0 2 0 . 3 i 5 . 0 I-. .. ..I.. 90 . 0 . so . 3 h Q . l ._..I. 1 .96.7a . . . . 2 7 3 ~ 0 . 7

....... - . . . .

. . . . . -. . . -. . .___. __ ...

......... ....... ...

. . . . . . . . . . . . . . . . .... .

eriomsizN P ~ R T I C L E SIZ,INC: . . . . . ............ ................ . . . . ~- .......

n I A M E T F:P b , K I C H T 3 PEP C I I M % C. R / SC F' I ) h1 i; / h C '4 I) S T A G F I ~ I C R C I ~ J S ) r M I I I L T C R 4 ~ ~ S ) STAGF <OPPER V I A Y PER S T 4 G E PF:R S ' P A G F :

. . . . . . . . . . . ................ . 1 > 8 . ~ 3 U 49-93 44.49 3.962 37 0 9 068.7

? R.3O-S.lh 15.26 13.60 ~ . .55.51 . 1..21.1011. . 2 7 7 1 . 6

3 5 .1 6 - 3 . 4 P 17.43 1 5 . 5 3 41 . Q 1 1 . 3 8 3 2 1 c ) 3165.7 . . . . . . . . - .. - .. . . . . . ... - . . . . . . . .

4 3-.48-2.3s g . 5 3 7 -50 26.3W 0.67hY2H 1549.2

5 2 . 3 5 - 1 . 4 9 1 1 . 4 0 in. I 6 .. 1R..7R . . . . 0.91-14.6~7 . 2 0 7 t j . s

1 . 4 9 - 0 . 7 2 5.RR 5 . 7 4 H . h Z 0.46hh28 l o b 7 . O -

c . . . . . . . . . . . . . . . . . . -~ . .- . . . . .......

7 n -7 2-0 .4 ? 2.09 1 . R h 3 . 3 ~ n. ic .5859 359,io

H 0.42-0.16 0.24 ... 0.21 . . 1.5.1 n . 0.1 9 o.4b. 43.59 - -

FTCTC:P < 0.25 1 .Oh 1.30 1.30 0.1.15Hh? 2 6 5 . 1 6 -. .............. - . . ... ._ . . . . . - ...

... . . ...............

......... . _ - ~ . .- . . . . . . . . . ..~ ...........

...... ................... - ~.

. . . . . . . - . ....... _ ........... .- ......... . . -. .... ..

A N D F R S E N P.4RTICLE S I Z I Y C - . . . . . . . . . . . .. .

n r P M ~ E . I , P : R NFTkVT % PFW CllMS C H / S C F I? 'il C / F: C ' A r)

S T h C F f w f C ' P d & S ) ( ~ I l , I . I G R A M S ) S T A G E <I lPPER DIAt4 PEW STAGE PER S'rAG).:

1 > 8 .90 17.R4 23 .R? 1.625128 3719.4

2 R.90-5.54 i 3 . n 7 17.44 76.11 .... l . l f i t i i 1 5 2 . 2714.S

3 5. s4-3 .7 3 i 5 . i n 2 0 . 2 3 58.67 1.375529 314E.1

4 3.7 3 - 2 . 5 3 12.19 1 6 . J 3 3H.44- 1 .110444 2541;h

22.1 I p.781592 1 ' 7 H a . 8

....... . . .. ....... __ . ._ .. -. .

.... - . . . . . . . . . . . ........ .~ . . . . . . . . - -

5 2 .53 -1 .hO H.SR 11 .4? . .~

h 1 .h0-9.78 4.22 5 .h5 10 .62 n . 3 w zs .i I c, 8 7 9. H 2

7 n.7H-IJ.46 1.44 1 . 9 3 4.91 0.1 3 1 1 7 6 3on.22 _ - . .. . ..

FTLTER < 0.28 1.63 2.18 2.1H 0.1434H 4 ... , . ...... ... - ......... - .

3 3 9 . 9 4

....... ...

1.420 . 0.513. ~ . o.ois 335.0

. 0 . 3 3 . 74.66 ._ 6. Hc) 1 1 3 . 15565.7

.. 1 .on . . . . . . . . .

- .

.. . . . . . . . . . . -. _. .. -. . .......... . . . .

. . . . . ... - ......... .- ._ ............ -~ ........... - -. .

1

. . . . . . . . il

..... - . .......... ~ ~-

. . . . . . . . .

3 A . n 3 - ~ . q q 9 . 7 1 9 . 9 3 80.P4 n . n Q 2 I s 4 4 . 0 3

'3 4 . 9 9 - 3 . 3 6 1 0 . 7 3 1 0 . 4 8 7 9 . 1 1 o.on23H t 5 . 4 5 ....... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4 3 . 3 4 - 2 . 2 7 9 . 4 5 9 . h 7 6 8 . 1 3 o . o n ~ n ~ 7 4 . H O

5 7 . 2 7 - 1 . 4 4 1 0 . 9 4 1 1 . to . . 5 8 . 4 6 .n .p !)2 4 2 7 5.55 ..........

6 1.44-0.hq 0 . 6 4 9.R6 4 7 . 7 1 0 . 9 0 2 1 3 9 4 . a q

7 0. b 9 - 0 . 4 1 1 0 . 1 5 10i.38 3 7 . on 0 . 0 0 2 2 5 2 5:is

R n . 41 - 0 . 2 s i 7 . w . 1 7 . 4 4 . . . . 2 7 . 0 2 .... n . 9 0 3 7 8 2 q.56

. . - ... . . . . . . . . ~.. .~

. -

FTLTFR < 0 . 2 5 9.36 0.58 9.SA I). no 2 n 7 7 4 ..7 5 - ................ _ _ - ...... _ _ . ......... .- . - _ ..

. . . . . . . . . . . . . . . . ....... -. ... . . . ..... .- .

....... ... . . ........ ... . . . . . . . . . . . .~ -

. . .. - .... . ........... - . - . . .....

. . . . . . . . .

6 . 2 C a l c u l a t i o n Formulae

PARTICULATE CALCULATION KEY

C

CO2' 02' N 2 r co

cP Dn E

$ E A ~*

EF

EFc

EHI

En

P E

Esb F

FC

GCV

% I

% M

Ma M,

Mw

Mwd

'b

L

2 = Stack area (ft )

= D r y particulate concentration - Gr/SCFD = Percent by volume (dry basis) in flue gas

= Pitot tube correction factor

= Sample nozzle diameter (in.)

= Dry particulate emissions - lb/hr = Percent excess ai=

= Emissions by F Factor - Lb/MMBtu =

= Emissions by actual heat input - Lb/MMBtu

-

Emissions by Fc Factor - Lb/MMBtu

Average normal emission rate (non-soot blow)

= Prorated emission rate

= Emission rate during soot blow

= F Factor (SCFD/1MMBtu)

= Fc Factor

= Gross caloric value of fuel fired (9tu/lb)

= Percent by weight of fuel fired

= Sampling isokinetics

=

= Mole fraction of dry gas

= Front half sample weight (milligrams)

= Molecular weight of stack gas

=

= Barometric pressure ("Hg)

Percent moisture by volume in stack gas ,

Molecular weight of &~y stack gas

-

'm

'S

*'S

QA

QS

Tm

Ts

Tt

'm

T

Tsb

V mstd

vS

V- W

'wgas

Average o r i f i c e pressure drop ( "H20)

Stack p res su re ("Hg absolu te)

Veloci ty pressure ("H20)

Stack gas f l o w rate, s t a c k condi t ions - ACFM

Stack gas flow rate , s tandard condi t ions - SCFMD

Time u n i t i n opera t ion per day (hours )

Average meter temperature (OF)

Stack temperature (OF)

Time u n i t blows soo t p e r day (hours )

T e s t time (minutes)

V o l u m e of gas sample2 a t meter condi t ions - f t 3

Volume of dry gas sampled a t s tandard con2i t ions -

- .-

f t 3

= Stack gas v e l o c i t y

= M i l l i l i t e r s of w a t

a t stack condi t ions - 52s

r c0ndense.d i n inp ingers

= volume of water vapor a t 7OoF and 29.92" Hg, ft 3

PARTICULATE CALCULATIONS

The following are the bas ic equations used i n c a l c u l a t i n g Lke data L as found i n t h e f i n a l surmnary.

1. Volume o f , d r y gits sampled a t s tandard condi t ions - 70°F, 29.92"8g, ft. 3

3 2 . Volume of water vapor a t 7OoF and 29 .92" Hg, f t . .. . .

= 0.0474 x VG ',gas

3 . 4 Moisture i n s t ack gas

gas 1 0 0 x vw

% M = 'mstd + ',gas

4. Mole f r a c t i o n of dry gas

5 . Average molecular weight of d ry s t ack gas

M Nd = (4 CO2 X -44) + ( % 02 X .32) + ( 4 N 2 X - 2 8 ) + ( % CO It . 2 8 )

6 . Molecular weight of s t a c k gas

M W C ( M Wd X Md) + 1 8 (1 - Ma)

7. Stack ve loc i ty a t stack condi t ions , fps

vs = 85.48 x c P j F

7 2 . Average stack velocity at stack conditions, fps

wheredAPS(Ts+ 4'60) is the average square root of the product of the velocity head and the absolute stack temperature.

- 8.. Stack gas flow rate, stack conditions, ACFM

QA = 60 x Vs x AS

9 . Stack gas flow rate, standard conditions, SCFMD

. . 1062.6 x Vs x AS x Md x Ps - (Ts + 460) Qs -

10. Percent isokinetic

17.24 x (TS t 460) X Vmstd 2 % I =

V, x Tt x P x Md x (D,) S

11. Dry particulate concentration - Gr/SCFD C = 0.01543 x Mf

",std

12. .Dry particulate emissions - l b / h r

E = 0 . 0 0 8 5 7 2 x C x Q, I

13. Particulate emissions by actual heat input - Lb/,Wtu - E - mtu/Er

14. % Excess air at sampling point

100 x ( % 02 - 0.5% CO) (0.264 X % N2) - ( % O2 - 0 . 2 % C o ) % EA =

i

15. F Factor

I O 6 ( 3 . 6 4 % H ) + ' : 1 ; 5 3 % C i + (.57%S) + (.14%N) - ( . 4 6 % 0 ) F = GCV

1 6 . Fc Factor 3 2 1 l o 3 %C -

Fc - GCV

17. Emissions by F Factor (Lb/MMBtu)

- CF 20.9 - 20.9-% O2

18. Emissions.by ?c Factor (Lb/MMBtu)

CFC 100 EFc = m % c02

19. Prorated Emissions

Lsb T - E = En + (Esb - En) P

. ~

.- PI , P PJT Lr!C A T I (J P I : P T C H V f I N I? , C P ................... . ~ --___ [IN I T TESTED : - C A L C I NFIH t! 1 0 u TLEr

.... . ............. - . . . . . . . . . . . . . . .

PA RTT Cl. 't$ A TE .~ ~ i, y I N WFTRIC I I r iTTS

.~ . . .- . . . . . . . . . . . . . . . . . . . . ......... - D F S C R T PT I Opt U hI 1 T S i 2 3 AVERAGE

GFFIFRb I., PA T A I>ATF f l F H l i Y N A P n ' 4 F T F I C PHESSIIWF YM.HG 7 6 2 . 2 5 7 6 2 . 2 5 '762.25 STACK PI?ESSUHli, AFpS., M * . H ( ; .. __ 7 6 2 . f i q .... -. ....... 7 h 2 . 5 9 7 6 2 . 5 9 . . .- .... - ....... - STACK AQI.:A u 2 0 .079 r i . n 7 9 0 . 0 7 9

7 2 . 0 1 0 q . 3

25.1130 I h5.2

43 . 19.5h 2 4 . 1 2 11.538

-1 1 4,

9h.O l 9 9 . S

2 J . 0 7 3 1 6 5 . 7 114. 40.

79.56 - 2 4 . 6 6

Q . 5 7 4

. .

0 6 . 0 1 0 2 . 7

73.065 105.6

i t a . 3 9 .

29.56 23..*6 0.51)7

. . . .

1 1 . n 0 . 0

H2.4) 49.3

i i0-2 .-a 1 . 4 8 I . S h 1 . 5 2 3 l ) J

1 0 6 . 9 . . .

2 4 . .15 h 1 6 5 . 5

1 lh. 41.

-. ..... ......

................... 7.9

1t.I)

4 7 . 7

......... .......

. . . 30.56 1.9.68 1 5 . 6 2 . . . . . . 2 1 . 0 5 . . . .

. . . . 0 .Q1 ' . . n.no 0 . 0 0 9 ! nu o . on n n o 0 . n on n o 17. 0 no o o o . i ) ! j n 11 o

.............. 20.93 11.11 ........ -. ..... 1 ! ? . 2 4 1 4 . 3 3 3 5 . 8 7 217.1 8 1 7 . !i.- 24.51 . . . . . . . . . . .

ENGLISH TO METRIC CONVERSION FACTORS

FROM ENGLISH TO METRIC MULTIPLY BY

DSCF DNm

DSCFM DNm /min Tons/& M g / h r 0.9072

o. 02832 3 3 0.02832

g r / D S C F g / D m 3 2.288

lb /h r K d h r 0 .4536 lb/ ton . W/Mg 0.5 O F OC -32, x 5/9*

F i r s t subtract 32 from O F temperature, then m u l t i p l y by 5/9.

PARTICLE SIZE CALCULATIONS

Operator Duct Dimensions

I m p a c t o r I.D. Nozzle S i z e : d n ( i n )

P i t o t F a c t o r : F, Meter Temp: Tm(deq F )

Clock Time Meter Rate: %(cfm)

P S t - 1) S t a c k Pressure: P, = Pb + - - 13.6

- L

inHq +In=

%A20 2) Mole F r a c t i o n D r y G a s : = 1 - - = 1 - - = 100 100

5 ) S t a c k Gas Velocity: V S t = 8 5 . 3 5 x (F,) x AP X ( T S t + 460) ps x MW

-fPS J-- - x ( + 460) = = 85.35 x X

X

6) Sample Rate: Qn = .327 x ( V s t ) x (dn 2 )

= .327 x (- ) 2 = ACFM

T, + 460 X M d PS

0 ' 7) Meter Fate: = (an) x- p- x

m T s t + 4 6

Cfm - + 460 - + 4 6 0

=

= c 1 0.5625

06-4-80

I I L

I ,. .

6.3 Field Data Sheets

6.3.1 Particulate Testing - Baghouse Inlet

BAROMETRIC PRESSURE, in. Hg

OPERATORS -k?J?&m . SCHEMATIC OF TRAVERS

ES-045 - FIGURE 2

. . i

-- -~ . .. . . . . ~.

Ispiage: V o l (=IlII)

I

Si l ica Gel (GI. 1

(w) = weiqhr of n c i s t u e ccllected = . . . - .. . .. -

\ *

.. . .. .. .. . . . . .- .. .- . -. .

v,

a a

Y

c 0 0 -I

L

z C

1’

i

r

. .s2 . '3

L,

=

u Y 01

a c

b

*\i F

i

i

6.3 .2 P a r t i c u l a t e T e s t i n g - Baghouse O u t l e t

PRELIMINARY VELOCITY TRAVERSE

? L A N T 4

/2,5 I, STACK 1.0. BAROMETRIC PRESSURE, in. Hg STACK GAUGE PRESSURE, in. H20 OPERATORS b d .-Y& -

TRAVERSE VELOCITY TEMPERATURE

NUMBER

- ES-045 .

FIGURE 2

I I

4aa AVERAGE

( W ) = weight sf scistlt-e csllected = - . . .- .. __

3 MoistL-e by Valme =

I

02-4-32 . -~ .- . -. - . . __ .. . __ - .. . . .

L

Q

m m E L 1 O h 1 0 Y E m u r i

. -

Q W - a -1 m

0,

e, C .

"l Y c 3 L

4

a . c:

m m = a O U 3 0 at" m

' 0 C Y

' I

I r 0

L

II I T

n . c:

( ' I I I

.[ . cn m 0 rc m

6 .3 .3 P a r t i c l e S i z e D i s t r i b u t i o n T e s t i n g

05-4-60

Cswnents :

05-4-80

PARTI= SIZE DATE S m

I I

05-4-ao

I I

I

I I

I I I

- 05-4-80

I

6.3.4 Opacity Readings - Baghouse Outlet

VISIBLE EXLSSIONS FIELD DATA

..

% Opacity

VISIBLE EMISSIONS FELU DATA

Date S-Jb I S , 1580 Job Number

Observer W a a ~ f - ' ~ D. - H O P & 1u-7 P l a n t & Location .I cold' %ad

I

Stack

Observation Began 1355- Ended / l o o Sky Condition U c e q

Distance from &L'7 Height I T ' P M V ~ Direction

2000 - 2917

% Opacity

96 Upacity

C orrunents :

VISIBLE EXISSIONS FIELD DATA

% Opacity

C om.ents:

..

76 Opacity

Comnents:

VISIBLE EMISSICNS FIELD DATA

% Qpacity

% Opacity

C aments :

6.3.5 Opacity Readings - Stucco Silo

EPORT NO. PAGE Or

VISIBLE ENISSIOXS FIELD DATA

Date JL.19 1 ' 5 , 1 4 8 W Job Number COLD BOND

Observer L ~ ~ R R L U 9 +j o pk 9- S . P l a n t & Loc;ltian /?ic+inuw\ L 6 t L I F .

Observation Point S+UCLO 5 IW Wind 6r Speed BaClEzc, ; lo -jsm$

S t a c k Distance fromh60'Hei&t Direct ion FRO- UJW

. Observation Began I130 Ended 1230 Sky C m d i ~ i a n ~ C ~ ~ ~ R

oorravnnoy> rrkrrJ & I S

OW-%-

% Opacity

; RE? P A G E 2 . 3

C omerrts :

- TEEPORT XO. R _- 7 PAGE 7 O f 3

6.3.6 F u g i t i v e Emission T e s t i n g - S t o r a g e Bin Area - Conveyor

_- I

6.4 List of Apparatus and Calibration Data

LIST OF APPARATUS

Location

RAC Box No.

AH@

Probe No/C P

Nozzle Diameter

Inlet

5-2166

1.87

040-005/0.89

0.255"

Outlet

5-1856

1.97

Test 1 - 054-002/.88 Test 2+3 - 316-48-002/.87 Test 1 - 0.259'' Test 2+3 - 0.249"

UUBRATION

I - - - 1

i

I I I i

1 I I

1 1

z o w j'

NOZZLE CALIBRATION

Calibrated by

Nozzle

number' identification

. -. Dl'

I in. D31

where:

D1'2t3r = nozzle diameter measured on a different diameter, in. Tolerance = measure within 0.001 in.

AD = maximum difference in any two measurements, in. Tolerance = 0.004 in.

. . - - . . D = average of D1, D2, and D3. avg

Nozzle calibration data.

12

CALIBRATION

ORY GnSMm3 h ORIFICE

14

7J

..

0.110

0.147

DArE 7 l l a / 8 0 Y R E R SOX NO. / 8 r b

r' .

c

I I

, -

I I

- - 9 -

97

FLOW 1

I i i I i

I I I I I I

F, = b..

. g7

F, =

new - F, * - - y-

Fs = - i -FLOW

... __.

Fstd = 1.00

N O Z Z L E CALIBPATION

Nozzle

number i d e n t i f i c a t i o n i n . O1

2 6 3

Calibrated by d . +SO I ' i J J

02, in . i n . D 3 '

. - A D , i n .

O O G 25q

where:

= nozz le d i m e t e r measured on a d i f ferent diamete:, i n . 01'2*3t Tolerance = measure within 0.001 in .

AD = maximum di f ference i n any t w o measurements, i n . Tolerance = 0 . 0 0 4 in .

D = average of D1, D2, and 03. avg

Nozzle cal ibration data.

12

s

1

a

I

. , I -

.,

6.5 Laboratory Data

I

I

7

. - I

Test&

2

3

2

3) 6% 6

6.6 Project P a r t i c i p a n t s

r-

/ '

The fol lowing YRC personnel p a r t i c i p a t e d i n t h e t e s t program:

J o e l Burke Maria Denaro Warren Hopkins Richard Keith Richard Nowak Sabina Strautman

Apri l 9 , 1980

X r . Warren Hopkins York Research 1 Besearch Drive Stamford, Connecticut 06904

Dear Warren:

Please be advised t h a t you successfu l ly coupleted our recent "Visible Emissions Evaluation" Course. Having p a r t i - c ipated in the smoke evaluat;on,sessions o n Apri l 1-3, 1980, you m e t the following c e r r i f i c a t i o n c r i t e r i a :

1) The average deviat ion f o r t he sets of 25 black smoke and 25 white smoke ex iss ions w a s l e s s than 7 . 5 % .

2) The devia t ion of each readiog w a s 15% o r l e s s .

3) A minisum of 250 readings f o r 211 h i t i a l c e r t i f i c a t i s n .

This c e r t i f i c a t i o n is v a l i d f o r six months from the da te x;.ms 1mlrOlMtmu

'39 is91 I y s r m m m

J U 3 i n ldoo4sz.Ip1z ;TOU completed your t e s t i n g .

7 1 - \ E n v i r o n p n t a l S e n y c e s S?ec ia l i s t Bureau o f A i r Qual i ty Control '

6.7 Work Assignment

! ._

I - .

Resexch Triangle P a r i N.C. 27711

~~

~ i s C R l P 1 ~ 0 ~ :

The Contractor s h a l l perform a n emission t e s t i n accordance w i t h t h e bas i c con t rac t scope o f work f o r t he Emission Measurement Branch, and as se t f o r t h i n t h e at tached "Source Sampling and Analys is Schedule" a t t h e f o l l o w i n g s i t e :

Company Name: Locat ion: Richmond, C a l i f o r n i a Indus t ry : Gypsum P r o j e c t NO. : 80-GYP-5

Gold Bond Bu i l d ing Products

The Emission Measurement Branch's Technica l Manager i s Dennis Holzschuh , M a i l Drop 13, EMB, ESED, OAQPS, Research T r i a n g l e Park, biorth Caro i in ,27711.

UDon n o t i f i c a t i o n of approval of t he proposed source t e s t repor t . t he Contractor s h a l l prov ide 10 copies Of the f i n a l r e p o r t with appeiidices and 10- copies as a sumiiary w i thou-endices.

A l l p r e t e s t survey, proposed f i n a l , and f i n a l source t e s t r e p o r t s and SOTDAT D a t a Forms s h a l l be- ik ibmi t ted d i r e c t l y t o J . E. McCarley, Emission Measurement Branch, ESED, H a i l Drop 13, Research T r iang le Park, Nor th Caro l ina 27711.

- . ............... ...... - __-

. . . . . . . . . . - . . . ... . . . . . . . . .._. ..

.