AP-42 Section Number: 9.9.1

Reference Number: 27

Title: Source Test Report on Measurement Of Emissions From Cargil, Inc.

Environmental Enginering, Inc.

1972

- 72-CI-28 (GRN)

SOURCE-TEST ‘REPORT ON MEASUREMENT OF EMISSIONS FROM

CARGILL, INC. SIOUX CITY, IOWA

FOR ENVIRONMENTAL PROTECTION AGENCY

UNITED STATES GOVERNMENT THOMAS E. WARD

PROJECT TEST OFFICER ..~ J - . -

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TABLE OF CONTENTS

Introduction

Summary of Results

Location of Sampling Points

Sampling and Analytical Procedures

Appendices

A. Pa r t i cu la t e Emission Calculations

B. Plant Operating Data

C. Field Data Sheets

0. Complete Sampling Procedures

E. Field Test Log

F. Projec t Pa r t i c ipan t s

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INTRODUCTION

Particulate emission t e s t s were performed on three separate

sources located a t the Cargill, Inc. Feed and Grain Mill i n S ioux City,

Iowa. The testing was performed d u r i n g the week of June 19 , 1972.

The sources tested were the Hammer Mill, the Column Cooler

i n l e t and out le t , and the Pan Cooler i n l e t and outlet.

All three sources were controlled by cyclonic dry d u s t col-

lectors. Three, two-hour t es t s were performed on each of the five points.

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SUMMARY O F RESULTS

Summarized r e s u l t s of the p a r t i c u l a t e emission s tack tests

performed a t Ca rg i l l , Inc. a r e included i n Tables 1-5.

T h e Environmental Protection Agency ( E P A ) performed the

analyses.

Complete p a r t i c u l a t e emission ca lcu la t ion data a r e included

i n Appendix A.

Complete p lan t operating data co l lec ted by the EPA are i n -

cluded i n Appendix B.

4 ) 3'Ii.fZ EiJD 5- ) BAROidE 9'R I C P R E S S U R E , I I{ I/ G 6 ) M Z T Z R O R I F I C E PRESSURE DROP, IIJ H G 7 ) V O C DRY GAS iIETL'R COiiD. CUBIC F E E T

. 0 ) A VZ12ACE CI;S I.Io"Ti?R TL?I.iP€:"lTUR%. DEG F Y ) V O L DRY G A S , S . T . P . , CUBIC FEET

b: 1O)i 'OTkL H20 COLLECTZU. J!L 1 1 ) V O L H 2 0 VAPOR COLLGCTZD. S . T . P . . CU 14)PCRCEIr'T c 0 2 1 S ) PERCEiiT 0 2

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LOCATION OF SAMPLING POINTS

Sampling ports and points were selected by using the guide-

lines stated in Method 1 o f the Federal Register (36. F. R . 24882,

24883, December 23, 1971 ) . Figures 1-8 are diagrams o f the sources sampled,

Table 6 i s the location o f sampling points for each source.

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Pan Cooler I n l e t

1

In t e r io r of bldg.

Figure 1 . Top View o f Roof. a t 4 t h Floo; Level

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Whole Corn No. 2 Yellow

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Straigh

12" I .D . LL

)/hole Corn No. 2 Yellow

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.a Stack Extension (28" I .D.) .

I Figure 2. Hammer Mill System

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-4 ~ 5 t h Floor - -

I n l e t Sampling S i t e

(26" 1.0.) L-4 6 4 t h Floor r

r l s t Floor

Fan

t ----9

5 S t r a i g h t e n i n g Vanes r _- -- --I

Return t o

P e l l e t Mill( \ California P e l l e t Mill

PBasement

Figure 3 . Pan Cooler System

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I n l e t

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Sampling S i t e (16 7/8" I.D.)

~ 3 r d F l o o r L-, I ' ' r , , i , -zzizE!2:

Fan c Basement u I/ / I' , I -- ,--

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Pel 1 e t Mi 1

Figure 4. Column Cooler System

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60"

44"

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Sample Ports ( 2 a t 900) 28" I:D.

S t ra ighten ing vanes ( 2 panels a t 900, 21'' x 28") r -1-1

a t 4 th f l o o r level

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Figure 5 . Hammer Mill Exhaust

Roof a t 4 t h f l o o r level ./. ,.

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Figure 6 . Pan Cooler I n l e t 13

36" Stack Extens ion Sample Por t s ( 2 a t goo)

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Roof a t 4 t h F l o o r Level

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I n t e r i o r o f Cyclone

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l----l----l I I I I I P S t r a i ghteni ng Vanes

I ( 2 panels a t 90°, 31"x41 3/4") L - L - J

F i g u r e 7. Column Cooler Exhaust (Side View)

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7 2 - C I - 2 8 (GRN) SOURCE TEST REPORT

ON MEASUREMENT OF EMISSIONS FROM CARGILL, INC.

SIOUX C I T Y , IOWA FOR

ENVIRONMENTAL PROTECTION AGENCY UNITED STATES GOVERNMENT

THOMAS E. WARD PROJECT TEST OFFICER

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SOURCE TEST REPORT

PLANT TESTED: Cargill, Inc. Sioux C i t y , Iowa

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CONTRACT NO: 68 -02-0232-Task Order 9

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TABLE OF CONTENTS

Introduction

Summary o f Results

Location o f Sampling Points

Sampling and Analytical Procedures

Appendices

A.

8.

C.

D.

E.

F.

Par t i cu la t e Emission Calculations

P1 an t Operating Data

Field Data Sheets

Complete Sampling Procedures

F i e l d Test Log

Pro jec t Par t ic ipants

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INTRODUCTION

Pa r t i cu la t e emission tests were performed on three separa te

sources located a t the Carg i l l , Inc. Feed and Grain Mill i n Sioux Ci ty ,

Iowa. ' T h e t e s t i n g was performed during the week of June 19, 1972.

The sources t e s t ed were the Hammer Mill, the Column Cooler

i n l e t and o u t l e t , and the Pan Cooler inlet and o u t l e t .

A l l three sources were control led by cyclonic dry d u s t col-

Three, two-hour tests were performed on each of the f i v e points . lectors.

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APPENDIX A

Par t i cu la t e Emission Calculations

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E. I:. I. SOURCE S!J!PLING ROi.ENCLATURE SHEET

PB - Barometric pressure, inches Hg PS - Stack pressure, inches Hg As - Stack arcs, sq. ft. AS'- Effective area of positive stack gas flow, sq. ft.

TS - Stack temperature, "R Ti.1 - Pfeter teoperature, O R

- H AH - Average meter orifice pressure differential, inches H20 AN - Sampling nozzle area, square feet CP - S-type picot tube correction factor VI1 - Recorded meter volume sample, cubic feet (meter conditions) VC - Condensate and silica gel increase in impringers, milliliters Po - Pressure at the dry test meter orifice, PB +& inches Hg

:JPTS - Number of traverse points where the pitot velocity head was greater than zer:

- Average square root of velocity head,

c 13.d STP - Standard conditions, dry, 70°F, 29.92 inches Hg

_ _ - _ - - - - - , . . ........

VWv - Conversion of condensate in milliliters to water vapor in cubic .... feet (STP) .... i . VSTPD - Volume sampled, cubic feet (STP)

VT - Total water vapor volume and dry gas volume sampled, cubic feet (STP) W - Noisture fraction of stack gas

FDA - Dry gas fraction ;r'. MD - Molecular weight of stack gas, lbs/lb-mole (dry conditions)@- MS - ?folecular weight of stack gas, lbs/lb-mole (stack conditions) GS - Specific gravity of stack gas, referred to air EA - Excess air, %

-2 - Average square root of velocity head times stack temperature U - Stack gas velocity, feet per minute QS - Stack gas flow rate, cubic feet per minute (stack conditions) QD - Stack gas flow rate, cubic feet per minute (dry conditions)

QSTPD - Stack gas flow rate, cubic feet per minute (STP) PIS0 - Percent isokinetic volume sampled (method described in Federal Register)

Y - Particulate Lab Analysis, grams ESTP - Particulate Concentration, grains per standard cubic feet EM - Particulate Emission Rate, pounds per hour

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TOTALS .0136 I .0037 - I I I

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0.02 0.08

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P L A t l T - C A R G I L L SIOII;., C I T Y e I O Y A D A T E - 6 / 2 1 / 7 2 S T A CK - I1 Al!!lE R!.? I L L OUT L E 7 Kl?ATlll7R COJ~DI?IONG- C L P b R AflP C O L D A S ' - 3 . 30 S O . FEE? .?.?- 5145.2 n'.'G.?EI?.? R . T J f - 5 2 2 . 2 D,?I::R,l?l?S .R 1- 0. 2 7 6 Ill !!2O -- A P - 1 . 6 7 I i l 1!20 ArJ--o.000767 SO. F P r T CF- 0 . 0 3 VII- 6 5 . 5 1 7 C.? V C - 3 2 l.?L T O T A L ?:!?E- 95 HI!' NPT,?- 30 O R Z A T : AIR

Rllll 2 PDO!! 9 : 5 5 - 1 1 : 4 5 PR- 2t3.70 III ??I: PS- 20.70 Ir! I I I :

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BACK I lALF .0045 I . O O l i - - T O T A L S . a i 6 5 I .ooun I I I I I

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TOTALS - 1 6 . 8 4 8 9 I 5 . 9 9 0 3 BACK F A L F - . 0 0 1 2 I . 0 0 2 G

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PLAUT- C A R C I L L S I P U Z CITY. I O V A S T A C K - COLU!.!?l COOLl?R OUTLET IIl?AT!!,7T! COCDI?IO!!S- CLCA.?

DATE- 6 / ? 7 / 7 2 RUJ? 1 FRO" 17:20-19:45

P R - 2 0 . 9 ~ i i irC: PS- 2 8 . 9 I" I'G

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P L A N T - CARGI1.L .';IOU.? c r y . IO!.l.4 DATE- 6/23/72 STACI!- COLUIRr COOLER OUTLZT RUIl 3 PRO!! 1 1 : 1 1 - 1 4 : 0 6 Wl?ATRE.I C O I I D I T I O N S - CLI;'AR A N P COLD PI)- 2 0 . 8 IIJ HG P S - 2 8 . 0 I?! I!C A S ' - '4.35 50. PEET TS- 5 7 4 . 7 DEGRl?:FS R T u - 546.1 DEG?i?I?S R e- 0.71 I!! H20

T O T A L T I ? ! E - 1 1 0 ?!Ill N P T S - 4 4 O E S A T : A/ / : -_ AI?- '1.87 I I I R?O n i t - - C . o o o w i so.. FEET . CP- 0.03 vrr- 8 6 . 5 1 C P v c - 6 3 r fL

. PROliT BALF - ' - 0 1 4 1 I .0027 BACK HALF - . . 0 1 0 9 I ' . 0 0 2 1 T O T A L S - . . . 0 2 5 0 I .0048

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P L A / I T - CAI?CII,L S I O U Z CI!!'X, I O N A DATE- 6 / 1 1 / 7 2 S T A C K - PAf l COOL?!? IIILI?'? IIEATIiCR C O l ? P I T I O l l S - CLEAR A i J D COOL PR- 20.78 I / ] HI: P S - 710 I?! HI7

A S ' - 3 .69 SO. F r E T A!!- 3 . 0 4 rfi {IZO AI! - o.ooo31&1 sc?. PSE? cF- 0.e3 v!f- 110.191 I?? V c - 6 6 /<L ?:TAL .TINE- 1 2 0 M I / rims- 2 4 ODSJT: AIL

RII!! 1 FROW 6 : 5 0 - 9 : 1 0

ZS- 5 5 5 . 9 DEGR,?T?.T R : TM- 531.1 DECREES R If- O . 9 f l S 111 l!?O

FROllT FALF - 11.0507 I 1.4911, RACK RALF - ' .OO39 I . .0005 TOTALS - 1 1 . 0 5 4 6 I 1 . 4 9 1 9

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P L A N T - CARCILL I;IOlI>.' CITY, I O V A DATE- 6 / 7 2 / 7 2

VEATIIER COCDITION.7- CI).SAR ARD COLD A S ' - 3.69 SO. F E E T ZS- 550 DEC0EF.C R :zc- 5 2 g . 6 DZC:Rr.?S R . E - 1 . 0 9 5 I?I R 2 0 -- A l l - 4 . 5 7 IN I120 A l l - 0.0003h1 SO. FEET CP- 0.03 VPl- 1 4 4 . 6 9 1 CF V C - 8 2 I!L TOTAL TI l lE - 1-20 EUtI P1IPT.C- 24 O R S A T : AIL

STAG%- PA11 COO%.?.? III%,CT RUII 2 FPOM ~ : . Q ~ - ~ I : o s P.R- 2 0 . 9 IT1 fiG PS- 2 0 . 1 Ill RC

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P L A I I T - C A R C I L L .SIOUX C I T Y . I O H A DATE- 6/22/72 S?ACi:- PA/! COOLER I ! ! L E T RUIl 3 FRO!: 1 2 ~ 3 0 - 1 4 : 3 5 ~

I.'l7ATi!PR C O / l / l I T I O C S - CT,EAR A l ! n COLD P B - 2 8 . 9 1 IN RG P S - 29.1 I?! H I : A&?' - 3.69 S O . F.R.?T zs- 5 5 9 . 3 DF'GRTPS R , TI'- 535.9 D.?CR??FLS R E - 1 . 0 6 6 Ill H20 -- A!l- 11.32 I?! 1120 A H - 0.000341 SC. FET? C?- 0.n3 VI:- 142.783 C? V C - 8 4 PL T O T A L T I f f P - 1 2 0 /!IN f?P?S- 2'! OR.?AT: AIR

GRA I i ' S iS C F : G R A I I : ' S / S C F G R h I C S / S C F POUNDS /HOUR

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FRONT H A L F - 2 0 . 5 4 5 1 I 2.2979 BACK H A L F - ' . 0 0 9 5 I . O O l l T O T A L S . - 20.5546 I 2 . 2 9 9 0

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P L A I I T - C A R G I L L .SIOU% C I T Y , . I O V A DATE- 6 / 2 1 / 7 3 S?AC.k- PATI COOLER OUTLET .nu!? 1 FRO:! 1 8 : 5 0 - 2 1 : l l I!EATijER C O i l D I T I O N S - CL.EAR A N D COOL P R - 2 0 . 7 8 I!? HG- P S - 2 0 . 7 0 IF! FC A , ? ' - 9 . 5 1 SQ. FEET T z - 5 9 R . 7 DEGl?l?ES'R TU- 530.6 PrGREE.7 R e- O.Uh7 Ill 1120 A I ! - 0 . 7 3 Ill 1120 A N - 0.0003U1 S O . F E E T 0 . 0 3 VI1- 6 2 . 0 6 5 CP V C - Zb 1!L

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PJAIIT- CA:ARCILL S I O U X C I T Y , I O l J A DATE- 6/72/72 STACK- PAN COOLER OUTLs?T RUlJ 7. FRO!{ 8 : 4 5 - 1 1 : 0 5 FJEATlrER C O P D I T I O I I S - CLEAR P R - 2 8 . 9 1 I I I i!r: PS- 2 n . 9 1 I l l HI: A S ' - ' 9 . 5 1 SQ. F E E T TS- 5 4 9 . 1 DECR~T.S R ' ~ 2 - 5 3 3 . 7 D E : G R E E S ' R g- 0 . 5 4 5 .VI 1120 A!- 1.15 IPJ i n n n t r - - E . o o o j u i s q . .@EFT C P - 0.83 vt!- 7 7 . 2 2 5 CP vc-33 i!L TOT/.I, T I I . ~ F : - 120 I?IU wm- 4~ O R S A T : AM

1 8 1 2 1 2 = 1 Y ) t ' 5 0 = 2 0 ) 2 . f =

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FROIIT P A L F - .7494 I ' - 1 5 5 6 B A C K H A L F - ' . 0 3 4 7 I ' , 0 0 7 2 TOTALS - . .?E41 I ' .1628

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6 ),lSSil?lt'D IlOIS TURE r'Rk C T I O i i 7) i IU = (.lrlrxCO2) + ( . 3 2 x O 2 ) + ( . 2 8 x ( C O + R 2 ) )

( U ) x ( A S ' )

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APPENDIX B

Plant Operating Data

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A. Process Description:

The following mater ia ls are blended i n s p e c i f i c formulas t o produce a var ie ty of animal and poultry feeds:

pulverized corn and milo wheat middlings soybean meal cotton seed meal fish meal fea ther meal meat scraps molasses premixes, minerals and drugs

Corn o r milo i s fed by gravi ty t o a Prator hammermill. 6 t o n s of corn per hour through 7/64" diameter per fora t ions . verized corn i s boosted t o the t h i r d f l o o r by a 50 I-IP f a r . separates the corn from the a i r stream and drops i t i n t o one of two '2,000 cu. f t . s torage bins (#5 and #6). exhaust a i r i s returned t o the th roa t of the hammermill, (see F i g . 1).

The mixed feed formula i s placed i n holding bins which feed i t i n t o the California P e l l e t Mil ls . the p e l l e t mill and the material i s extruded through a d i e t o focm+peTlets approximately 3/16" diameter and q' long. Each p e l l e t mill produces 6.. ' t o 10 tons of feed per hour . The r a t e of production depends upon t h e <-'' formula of the feed b e i n g processed. be applied t o the p e l l e t s as they drop from the pellet m i l l s i n t o the p e l l e t coolers . Dust i s . app l i ed t o feeds which cause problems by clog-.. g i n g equipment o r bridging i n s torage bins. ' These problems a re r e t e a ' t o the ingredients i n the feed. mesh s ieve and has been died yellow. per ton of feed.

The'mill forces The pul-

A cyclone

A t l e a s t 50% of the cyclone

Steam i s introduced t o the feed material a t

Fine, calcium carbonate dust may

' .

The calcium carbonate will pass a .ZOO I t i s applied a t the r a t e of 30#

The pellets are cooled in e i t h e r a column o r moving pan type p e l l e t cooler . the product ion rate a t the p e l l e t mills. i n the basement area. Dust picked up from the p e l l e t stream is co l lec ted i n l a rge diameter cyclones located on the t h i r d and four th f loo r s .

The r a t e of pellet flow through the coolers i s dependent upon The p e l l e t coolers a re located

Air is pulled i n t o the coolers from the basement.

The dus t col lected i n ..... . . . . . . . . .. ' ' t h e ' c y c l o n e s i s returned t o the pel le t mills f o r reforming. . . . . . . . . . . . . . . . . . . . . . . .

- . . . . . i . . . . . . . .

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

. . . . . . . . -. :.<. . . ..

.. . . : B; Discussion .of Test: .. . . - . . . . - -

!I 'I 'I ic I 'I I 4 I I I I i I i ii c

Hammermi 11

The hammermill was grinding #2 yellow corn which by National Grain 'Standards, contains < 5% foreign matter and < 15% moisture. moisture check on a Endom sample of the c o r n e n t e r i n g the hammermill indicated 13.2% moisture. bins contained 12.3% moisture. This i s a normal moisture loss for a ,

grinding operation according t o Mr. Musech. The exhaust a i r from the cyclone contained approximately 2.3% moisture a t 85OF. was removed from the cyclone and a short extension was at tached t o the ou t l e t . A s t ra ighten ing vane cons is t ing of a cross made of k'' plywood, was in s t a l l ed . The vane seemed very e f f ec t ive i n d i s t r i b u t i n g the flow more evenly across the exhaust duct. a t the cyclone exhaust w i t h the EPA t r a i n (method #5) and a high volume sampler.

The f i r s t of three t e s t runs on the hammermill cyclone was conducted on .June 20, 1972, from 8:25 p.m. t o 11:02 p.m. Storage bins #5 and #6 were measured p r io r t o s t a r t i n g the gr inder and were found t o have 44 f t . and 11 f t . of f r e e space, respect ively. B i n #6 was f i l l e d a t 9:05 p.m. and the pulverized corn was diver ted t o b i n #5. The grinder was shut of f between 9:25 p.m. and 9:40 p.m. while the sample t r a i n s were ro ta ted 900 i n the s tack . There were no v i s i b l e emissions during the t e s t ing .

The second t e s t run was conducted on June 21, 1972, from 9:50 a.m. t o 11:45 a.m. Bins #5 and #6 were measured p r i o r t o s t a r t i n g the t e s t and were found t o have 29 f t . and 9 f t . of f r e e space, respec t ive ly . T h e , grinder was started a t 9:40 a.m. and run continuously d u r i n g the ~6es t= .~~s ,L

The grinding r a t e was steady and was calculated t o be 6 tons/hour on.. 2.: the basis of the b i n measurements and the operating times. There were no v i s i b l e emissions during the t e s t i n g . ducted on June 21, 1972, from 12:05 p.m. t o 1 :50 p.m. The grinding . .

a t 1:20 p.m., when the pulverized corn was d iver ted t o b i n #6. were no visible emissions d u r i n g the testing.

A

The pulverized corn en ter ing the s torage

The r a in cap

Simultaneous samples were taken

The t h i r d t e s t run was con-

B i n #5 r a t e was steady a t 6 tons/hour throughout the t e s t .

. . Pan Cooler

Pellet mill #3 is serviced by a horizontal (moving pan type) p e l l e t cooler and cyclone #173A. The i n l e t and o u t l e t of the cyclone were tested simultaneously u s i n g EPA method #5 w i t h impingers. cooler is produced by the Cal i fornia P e l l e t Mill Company, Model Number . ,

5HRS22. . i s 185 sq. f t . of cooling area:. Average p e l l e t bed depth on the moving

pans i s 7". .:? #173 pu l l s a i r .from the basement area'(720F).through the cooler and blows . ,~>j.:.- . . _ .

.~ .' - . i t t o the cyclone..' The New York Blower Model 452 has a 40 HP motor and . . , , . ~ : . . . . - . . . ro t a t e s 1800 RPM. --.The blower is capable o f , p u l l i n g 18,500 cfm.,with a -~ . . ,~ . . .:..:

The p e l l e t

The cooler i s 5 f t . wide, 22 f t . l o n g and p e l l e t s make a double . .-: . . . , ..

, . pa s s through the cooler r i d ing on moving, perforated metal pans. There .- . '.

. .. . , . . .

.:

., ~' . . . .

Cubes may be p i l ed . t o a depth of 9" i n this . .cooler . : Fan

. . . . . . . . . ._ s t a t i C p r e s s u r e of 7" water a t 914 RPM. : - . . - ..-, . / ..

I

The f i rs t of three t e s t runs was made on June 21, 1972, from 6:50 p.m. - 9:lO p.m. lowing ingredients was prepared f o r pe l l e t i z ing during the tes t period.

A 21 t o n mixture of beef c a t t l e feed containing the f o l - 'I \I 32% wheat middlings

30% cottonseed meal 17% soybean meal !I 5% molasses 16% minerals and premixes 100% 1

The feed was pe l le t ized in 160 minutes, g i v i n g a production r a t e of 7.6 tons o f pel le ts /hour . carbonate applied a t a steady r a t e .

The p e l l e t s were dusted with 550 l b . calcium :I

Visible emissions f luc tua ted from 'I 15%-50% opacity.

I !I I I I 0 , ' , -.: I I ,.. . . c

The second t e s t run was made on June 2 2 , 1972, from 8:45 a.m. t o 11:05 a.m. for run #1 was prepared f o r pe l l e t i z ing during the t e s t peri'od. were produced a t the r a t e of 6.1 tons/hour d u r i n g the operat ing time. The p e l l e t s were dusted w i t h 500 l b . of calcium carbonate. was taken of the dust co l lec ted by the cyclone. tuated from 15% opacity t o 50% opacity during the tes t . The v i s i b l e emissions were due t o the p e l l e t dusting operat ion.

The t h i r d t es t r u n was made on June 22, 1972, from 12:32 p.m. t o 2:40 p.m.

An 18 ton mixture of beef c a t t l e feed of the same formula used Pe l l e t s

A g r a b sample Visible emissions f luc-

. .

An 18 ton mixture o f c a t t l e feed containing the following ingre- ..<: ,. ..i ;. . . . . .

. . dients was prepared f o r pe l l e t i z ing during the test period. . . , , .

60.0% pulverized corn 25.0% wheat middlings 9.5% soybean meal 1.5% cottonseed meal 4.0% minerals and premixes

100.0%

_.. .: .. ~

jr" @- z

The p e l l e t mill was run a t a steady r a t e , producing 9 tons o f pellets/ hour. The pe l l e t s ,were not dusted.

The stack was observed from a dis tance o f 20 f t . and no vis ible emissions were seen, below and 150 f t . e a s t . peared t o have a constant 5% opacity.

The stack was a l so observed from the ground level 150 f t . W i t h blue sky as the background the plume ap-

. .

.. . . . : .

. . : Column Cooler : .- . . . . &. '::my':- ' :" :Pellet mill #1 i s served by two v e r t i c l e column type pellet coolers a n d , ' I .. . ' '

. . . .. . ;two cyc1,ones. Only one of the coolers was used during the tes t period. , ..::.The 'column cooler was manufactured by the Cal i forn ia Pellet Mill Company, . . , .

.. '-,the cooler. ,The

.t

diameter o u t l e t pipe extends 27" above the roof. and o u t l e t were tes ted simultaneously using EPA method #5 w i t h impingers. The ra in cap was removed from the cyclone o u t l e t and an extension and s t ra ightening vane was in s t a l l ed .

The cyclone i n l e t

The f i r s t of th ree t e s t runs was made on June 22, 1972, from 5:20 p.m. t o 7:45 p.m. A 30 t o n mixture of poultry feed containing the following ingredients was prepared f o r pe l l e t i z ing during the tes t period.

75.0% pulverized corn 15.0% soybean meal 2.8% wheat middlings 2.5% meat scrap 1.9% fea ther meal 3.8% minerals and premixes

1oo.o% The p e l l e t mill was processing a s imi l a r poultry feed when t e s t ing began a t 5:20 p.m. 5:50 p.m. and operated u n t i l 9:30 p.m. r a t e of 8 tons/hour. were no v i s ib l e emissions from the cyclone.

The second t e s t run was made on June 23, 1972, from 7:50 a.m. t o 9:45 a.m. An 18 t o n mixture of poultry feed containing the following ingre- d ien ts was prepared f o r pe l le t iz ing during the test period.

The mill was stopped a t 5:35 p.m. and r e s t a r t ed again a t

Dust was not applied t o these p e l l e t s , and there Pe l le t s were produced a t the

,_ .,q $. ,,.: , ,

10.5% wheat middlings ,.. ~

. . . _ .. 57.5% soybean meal .

10.0% meat scrap . _.. .:

7.0% fea ther meal 15.0% minerals and premixes 1oo.o%

The p e l l e t mill was run a t a steady r a t e , producing 6.7 tons o f p e l l e t s per hour . The pellets were n o t dusted and there were no visible emissions from the cyclone.

The t h i r d t e s t run was made an June 23, 1972, from 11:11 a.m. unt i l 2:06 p.m. A 30 ton mixture of poultry feed containing the following ingredients was prepared for pe l le t iz ing d u r i n g the t e s t period.

Testing was discontinued between 12:OO noon and 1:OO p.m.

18.75% soybeap 3.50% wheat n

I1 'I 1 I I I I I I I I I I i I i

!t

t

1

C. Process Data:

Test Run

1 2 3

Test Run

1 2 3

Test Run

1 2 3

. . . .. . . . . . . r '- - . . . . . . . . ., . , ? . . . . . . . - ,

. . - .. . . . .

HAMMERMILL CYCLONE

G r i n d i n g Rate Materi a1

6 T / h r #2 Yellow Corn 6 T / h r #2 Yellow Corn 6 T / h r #2 Yellow Corn

PAN COOLER CYCLONE

P e l l e t Production Dusting

7.6 T / h r 26.2 #/T

9.0 T / h r None

Rate

6.1 T / h r 27.8 #IT

COLUMN COOLER CYCLONE

P e l l e t Production Dust ing Rate

8.0 T / h r None 6.7 T / h r None 7.6 T / h r None

Remarks

No Visible Emissions

Visible Emissions

15%- 50% 15%-50% None

R ema r'k s

, No Vi s ib l e ........ . . .

Emissions ....... ....

. . . ~ . ., . . . . . . . . . . . . . . . . . . . . . >; . . . .

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.~ .

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APPENDIX C

Field Data Sheets

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APPENDIX D

Complete Sampling Procedure:

,. .... , .... : . . . . , . .~... . ._ -, .

..

Saiwl ,i nq Procc3ai-e I/---.--..-

Prior t o performing the actuGl par t icu la te emission t e s t s ,

cert.;in preliminary st;.cl: parane,ters had t o be estimated o r determined

for the source.

velocity head, rnoisture content, s tack d.iartieter, and number 0-F sampling

points .

This prel ininary data included the averaoe temperature,

The stack gas temperature was determined by using b imeta l l ic

therniometers and int!-cury b u l b thermometer:.

Velocity head measurements were determined across t i e s tack

diameter by us ing a ca l ibra ted S-type p i t o t tube with a n incline$.yoan:,-. . . . .

ometer. This data was used t o s e l e c t the sampling nozzle diameter. :.. = ' . .. . . . .

The approximate moisture content of the stack gas was deter- ;,'

The sanipl ing t raverse p o i n t s were selected according t o Method

mined by the wet bulb and dry bulb thermometer t.echnique. &- ' . .

1 o f the Federal Register (Volciiie 36, Nmber.247, Par t 11, Deceziber 23,

1971 ) . The stack emissions were sampled by us ing the following sample

t r a i n :

g lass f i b e r f i l t e r ; two.impingers w i t h 100 m l of d i s t i l l e d water; two

dry impingers ( the second impinger had a .standard t i p , while t h e f i r s t ,

t h i r d and fourth impingers had modified tips w i t h 1/2-inch ID openings);

a s t a i n l e s s s t e e l nozzle; a glass-l ined probe; a Gelnian Type A

. . . . .. . . . .

. . . .

‘I

i I I I I 1 i I i I I I i c i -1

a therica!ceter on the l a s t inipinger; a f l e x i b l e sample l i n e ; an a i r - t i g h t

piimp; rl dry t e s t cieter; and f i n a l l y , a ca l ibra ted o r i f i c e with an i n -

cl ined ii!anoiiieter.

t r a i n .

Figtire 6 sho!.rs a schematic arrangement of the sampling

S i l i c a g s l was n o t used in the four th impinger because i t did

n o t a r r ive with tile equipment, and there was none ava i l ab le i n the area.

After discussion with the Project Off iwi . i t was decided t o t e s t w i t h o u t

s i l i c a gel s ince the moisture was near ambient.

culations was determined by the use of the wet and dry bulb nethcd.

Because the s tack temperature was l e s s than 10G°F and the

The moisttire f o r ca l -

moisture content was low, the probe and the f i l t e r holder portions of the

sampling t r a in were n o t heated.

The impinger portion o f the sampling t r a i n was iced dovn t o . . *: .. ..y ” . . . . . . . . .

, I

co l l ec t the condensable n?oisture in the s tack gas . ...

Each point sampled across the s tack diameter was sampled a t an

i sok ine t i c sampling r a t e . j’” &,y .i

Sample Eecovery

Samples were recovered i n accordance w i t h procedures out l ined

in Nethod 5 of the Federal Regjster (36 F . R . , Mzrch 31, 1971) , Determination

of Par t icu la te Emissions from Stat ionary Sources.

The sampling t r a i n glassware, exclusive o f the g lass l ined

probe and the f r i t t e d d i sc f i l t e r , were soaked in chromic ac id cleaning

solut ion f o r two hours previous t o the preparation o f sample blanks.

probes were thoroughly washed i n chromic acid so lu t ion p r i o r t o t e s t ing

The

. . . . . . . .

. . . . .

. . . .

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

... . . . . . . .

. . . .

‘i -_ ‘ . ~ .. . . . . . . . . . . . . ... ... - .... .- . .- . . -~ - ~. . .

-

I

i I 1 u I

b u t were n o t soaked due t o their cuinbersome length.

glassviare v!as r insed extensively w i t h d i s t i l l e d r:ater following the

acid wash.

All sampling

All sxnples w2re tin-ned over t o the Project Off icer f o r

additional label ing and ana lys i s .

11 i ( 'I 'I I I I d I I I I I . I i U -

!

J

\\

W

I

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Fie ld T e s t Log

" ._ -+ ;. . . . . . . .. .. ... -, ,

'I 'E I II 'I II I I I I I I 1 ... r i

I

FIELD TEST LCG.

6/18/72 Left Crlai:d!, a t 1530 EDST, arr ived i n Sioux City a t 2230 CDST.

6/19/72 Iv'ent by t o pick u p equipinent. Kine of the twelve boxes made i t . Probes, s i l i c a ge l , t o o l s , and uiiibilical cord did not make i t .

\-le met with Tom Nard and p lan t o f f i c i a l s t o discuss sampling program. f o r building stack extensions and straightening vanes.

Called o f f i c e and requested additional probes.

Unloaded equipment and proceeded t o ge t material

G/20/72 Finished se t t i ng ' u p sampling equiprrent and Duilding..s.&ic6: extensions . j .

Probes arr ived a t 1015. k!e were ready t o sample the Harmer Mill Outlet a f t e r noon. Ne were requested t o wai t u n t i l ' f &- 2

two EFA engineers arrived so tha t comparative tests could be made with the EPA t r a i n and a inodified hi-vol sampler.

After the EPA sampler was s e t up and we leak tes ted our t r a i n , WE began t e s t i n g a t 2030.

.. _.

No s i l i c a gel was used.

Because the flow r a t e from the s torage b i n was not detectable w i t h t he velometer ( l e s s than 10 f.p.m.), EPA did not re- quest any t e s t s u s i n g a hi-vol sampler.

Test ended a t 2302.

. . . . . . . - . . .

. . .. . .

. - * . ...., . . .. ... . _ . . . . - ~. .. - -~ - ~ ~ . . . ~. . L: . .

6/21/72 Second t e s t on the Hammer Mill began a t 0955, and ended a t 1145.

l e h z d i o wai t on p1ar.t process be-fore sat i ipl ing.

The f i r s t run ( i n l e t and c u t l e t ) on the Pan Coolci- b q a n a t 1850 and ended a t 2113.

Third t e s t fJEgaI1 a t 1210 and cnded a t 13.50.

6/22/ 7 2 Seccnd run on Fan Cooler begin a t 0845, ended a t 1105. T h i r d run began a t 1232, and ended a t 1440.

lrle becjan f i r s t t e s t on the Column Cooler ( I n l e t and Outlet! a t 1725, and plant s h u t d&;n 1735 and i.lzs down u n t i l 1802. We continued sampling and finished a t 1951.

6/23/72 Second test on Column Cooler began a t 0750 and ended a t 1005. because of p lan t shutdown. We resumed sampling a t 1320 and ended a t 1420.

After cleanup and packing equipnent, we gave the EPA Project Off icer the samples.

We l e f t Sioux City a t 0730, and arr ived i n Gainesvilley- a t 1530.

T h i r d run began a t 1100 and shirt doiw a t .1200

. . < ....... . . . .

... :

?' 6/24/72

:

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P

APPENDIX F

Project Participants

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v 1. II 11 13 I I I I .I I I I I I I I I 1. I-

Environmental Engineering, Inc. P.!ame T i t l e

~

John IKooqle?,. P i l . D . , F . E .

John Dollar, EIT, I4.S.

George: Allen, S r . Technician

RoS2r.t D u q a n , S r . Technician

Eric Johnson, Sr. Techni c i a n

Project Director

Project l+mager

Environ!nZntal Special i S t

Environn!clltal Special i s - t

Envi ronmenta! Speci a1 i s t

Envi roiimental Pro-tec.ti an Agency

T i t l e Nan? - Thornas E . Ward Project Test Officer ..:$ :: Ken Koodard Project Engineer

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~ ... _.. , . . . ~ . . , . .. ..:... . . - . . _ . .... - . .