Background Report Reference

AP-42 Section Number: 1 1.17

Background Chapter: 4

Reference Number: 47

Title: Report of Determination Stack Emission Envestigation Plant No. 4, Test No. 10 and 11

National Lime Assoc

National Lime Assoc

February 1977

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E P O R ? O F DETERHINATION

STACK EMISSION INVESTIGATION

PLANT NO. 4

TEST NO. 1 0 and 11

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FEBRUARY 9 , 1977

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=PORT OF DETERMINATION

STACK EMISSION INVESTIGATION

PLANT NO. 4

TEST NO. 10 and 11

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FEBRUARY 9, 1977

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TAULE OF CONTENTS

MTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P a ge 1 e

SUMM4RY OF RESULTS.. . . . . . . . . . . . . . . . . . , . .. .. . . . . , . . . .. . . . . ..... Page 2

PROCESSING OPERATION DESCRIPTION.. . . . . . . . . . . . . . . . . . . . . . . . . . . Page 3

LOCATION OF SAMPLING POINTS .................................. Page 4

SAMPLI?JG AND ANALYTICAL PROCEDURES.. . . . . . . . . . . . . . . . . . . . ... Page 4

APPENDIXES:

SUMMARY O F RESULTS. ... ...... ... .. . . . . . . . ... . . . . . . . Page 7

PARTICULATE RESULTS AND CALCULATIONS.. . . . . . . . .Page 8

SULFUR DIOXIDE RESULTS AND CALCULATIONS.. . . . . . Page 23

FIELD DATA.. .. . . . . . . . . . . . . . .. . .. . . . . . . . . .'. .. . . . . .... Page 25

BENDM INSTRUCTION MANUAL MERPTS.. . . . , . . . . . . . .Page 38

SULFUR DIOXIDE SAMPLING PROCEDURES.. . . . . . . . . . . .Page 60

CALIBRATION DATA.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Page 62

PRELIMINARY INFORMATION DATA.. . . . . . . . . . . . . . . . . . .Page 64

tr ',

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REPORT OF DETERMINATIONS STACK EM1 SS I ON INVES TI GAT1 ON

TEST NOS. 10 AND 11

FEBRUARY 9, 1977

INTRODUCTION

The l imestone c a l c i n i n g o p e r a t i o n a t P l a n t NO. 4

produces gas streams t h a t p o t e n t i a l l y con ta in both p a r t i c u l a t e

ma t t e r and s u l f u r d iox ide . Nevada Tes t ing Labora to r i e s w a s

given the assignment of t e s t i n g t h e f i n a l s t a c k s f o r t h e s e

contaminates.

P l a n t No.4 o p e r a t e s t h r e e k i l n s . Number 3 k i l n is t h e

l a r g e s t , and w a s s 'e lected fo r sampling. Sampling f o r p a r t i c -

u l a t e w a s done on January 13, 1977, and s u l f u r d iox ide on

January 25 and 31, '1977.

of the fo l lowing sections.

R e s u l t s from these tests are pa r t

SU hlhM RY OF RrSULTS I r-“ I I I I I I

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The par t iculate r e su l t s a r e summarized a s follows:

Stack - No. 3 Kiln . Pound Per Hour

Isokinetic (4) No. Pmr, (1) P m r a (2) Pmrav (3) Ratio. %

1 OA 8.32 7.76 8.04 93.2 1 OB 11.17 10.97 11.07 98.2

Average: 9.21

(1) Par t i cu la t e mass r a t e , concentration method.

(2) Par t icu la te mass r a t e , r a t i o of a r e a s method.

-

1 oc 8.43 8.60 8.52 102.0

(3) Average of two methods.

(4) Ratio of sampling velocity t o velocity in s t a c k a t sampling point.

P l a n t ’

Since the totdl processing rate a t N ~ . 4exceeds 60,000 pounds per

hour, t he allowable par t iculate emission r a t e is 40 pounds p e r hour.

be divided over t h e th ree kilns allowing 13.3 pounds pe r hour each (neglecting the

f a c t t h a t No. 3 kiln is la rger t h a n the o t h e r two). Al l of the t e s t s were below

t h i s rate.

This would

The t e s t s were all conducted in the p re fe r r ed isokinetic ratio range

of 90 t o 110%.

The sulfur dioxide test da ta is summarized a s follows:

Sulfur Dioxide Rate Pounds Per P a r t s P e r

T e s t NQ. Standard cf (dry) Million by Volume l l B 4.06 x 10-5 24s 11c 1.46 x IO-’ 88

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D < ~ t ; l h o t 1 1 Test 1 0 iiver.lgcd 34,060 c fm of total gas a t s tandard con-

dition or 32,900 c fm of dry gas.

would give an emission r a t s of 80 pounds p e r hour. Assuming a heating value

of 11,200 Btu pur pound, and a firing ra te of 95 ton pe r day, the t o t a l hea t

input . to the kiln is about 89 million Btu/hour.

sulfur dicxiilr enlission r a t e of .IS t imes t h e h e a t in millions of Btu pe r hour.

This gives 13.3 pouncls of s u l f u r dioxide per hour a s the allowable maximum.

A t t h e concentration found in Run 1114, t h k

County regulations call f o r

PROC CSS DESCRIPTION Plant

A t NO. 4 high calcium l imes tone is quarried, crushed, sc rernez , and

calcined. Ca!cining is t h e p a r t oE t h e operat ion of concern in th i s r epor t .

Lump liniestone (CaC03) is fed t o a contact prehea ter where the gasses

f r o m the kiln contac t t h e rock and p rehea t it t o near calcining tempera ture .

From here, it is fed t o t h e r o t a r y kiIn where it is calcined t o quick l ime(Ca0) .

The kiln is heated hy hurning gas or coal with coal being used a t the t i m e of

these tests.

cooled by air .

F rom the kiln t h e lime drops into a cooling chamber where it is

Tracing the gas s t r e a m , the air from t h e lime cooler, plus additional

a i r if necessary, is used to birm coal and h e a t t h e kiln. The h o t gxses from

the kiln pass tlu-ough the l imestone p r e h e a t e r and a r e than s e n t t o a bag house

t o remove par t icu la te m a t t e r .

lower t h e gas tempera ture and p r o t e c t t h e bag house. . From the hag house the

gas s t r e a m is exhausted t o the a tmosphere through a s tack.

Additional air may be added t o the s t r e a m to

There are three kilns, each wi th its own hag house and s tack . No. 3 ki ln is

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

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t he l a r c e s t , processing ahou: 600 tons p e r day ofi l imestone and burning about

82-95 tons pe r day of c o d .

LOCATION OF SAMPLING PORTS 1

Samplirg p o r t s were provided on 90' center l ines near t h e top of the

s tacks .

t h e top.

t h e s t ack inlet f r o m the blower behueen the bag house and t h e s tack .

fo rm surrounded t h e stack 57" below t h e sampling po r t s .

No. 3 s tack w a s 5.5 f e e t in d i a m e t e r and the p o r t s were 6 feet f rom

There was 24 f ee t of s t r a i g h t s t a c k between t h e sampling p o r t and

A plat-

Originally the re were two p o r t s on t h e stdck; f o r th i s sampling two

additional p o r t s were cu t marking four sampling p c r t s a t 90' intervals.

p o r t s were numbered clockwise starting a t t h e platform-access catwalk.

The

PROCESS OPERATION

The process was in continuous operat ion during t h e sampling f o r both

General descr ipt ion of t h e operation is con- par t iculates and sulfur dioxide.

tained in "Process Description".

I t was noted that t h e s t a c k t e m p e r a t u r e and flow r a t e s varied very

little duriag the sampling operation.

SAMPLING AND ANALYTICAL PROCEDUR€S

The procedures used f o r o u r determinat ions of par t icu la te m a t t e r were

in accordance with those specified by E.P.A. (Title 40, Part 60, nlethod 5)

using equipment manuEactured by t h e Environmental Science Division of Rendix

Corporation. Sections of t h c Rend& Operating Imt ruc t ions a r e shown in

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Appendix E and a r e in agreement with E.P.A. Mt. <:k.h! Y. .

The.equiprnent manufactured by Bendix iz i.,k! ::acie a s specified fo r

Method 5 except for : . (a)

(b)

A s ta in less s t ee l liner is used in thc pr&e instead of glass.

The glassware connections were ma.!<: wit.ii 'J'eflon-faced packing

gland joints instead of ball joints.

In work up, t he wa te r f rom the impinge?-!< WJ<; e ispora ted in beakers,

dried, and added t o the primary par t iculate catc!?. i'k cyclone catch was

added t o the acetone washings of the probe and L>.?ez ;+~miber.

also evaporated, dried, and added t o the primary .:a!ch.

This was

Because only one s t ack d iameter of stacI: Is:y?ji was available beyond the

sampling point and 4.4diameters ahead of t h e s ~ i ~ i j : i q ; ;mint, the s t a c k was

sampled a t 36 points, 2 min. being used a t each pi!>?. The probe. length

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prevented sampling the en t i r e diameter &om onc t:i&, so t he sampling was

done a t 4 por t s .

The procedures used f o r our sampling E,?:. ci.tl.<u dioxide were in accord-

ance with those specified by E.P.A. (Title 40, 17.n-t C;C, Method 6). The Bendk

equipment used for p a r t i d a t e was modified ti .c.xL-.b;;y with Method 6 a s follows:

(a) Three of the impingers were remcr,,:? .xd replaced with midget

impinger with suitable glassware c;?r.:?;,ci ims.

@) The uni t was operated without a y.::iid;+te nozzle.

(c) The flow was decreased t o avoid o..-+rl.r.~.ti;::z t h e midget irnphger. 0

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SUMARI ' OF RESULTS

--- )Runt-

I % C 0 2 - Vol Z dry

I NO, Emissions - p p dry

' t - x s . , ht- .

Tctal Catc i i - gr /SCF *dry

ar /CF 0 ;trick Coridi t i o n s I

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Dry p r o h and cyclone ca tch : Con La iner No.-

E x t m No. - LVei,!l:t. results r

Conb inc r NO. I& .; 5/15 15.3 3 / 1 k ? , j o Probe. cyclone, f L s k . and

ExI&No. - Wei&t rrsiiltfi !I3 4.7 n

-1wr C e u w r . u o .

' - front half of. tiltcr. acetone wash:

. . .. ." ' 5 1 I'! .r E Filtcr Papers and Ihy Filter Particulalc . .

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Filter number Container no.

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PARTICIILATE C1.EANIll' SJICET

Impingers and Imck l ~ d f of Container No. - filter, acetone wash:

Dry probe and cyclonv c.1 tch: ConLthc r No.-

Ext raNo . - Wt*ib;!it r e s u l t s n

4 9.4 0 4 3 Probe. cyclone. fhsk. ~ i i d Container No. r&z -. ... c u d - f r o n t of fiLLer. acetone wash:

Filter particulate wc 4 6 h t 4 S . G

Total particiil.il c weioht 14

Silica Gel 503.5 Weight after test:

48J.s Weight before test:

Moisture weight collected: 18.0

---- ----

hIoisture t o t a l

7 Conkiiner number: 1. n - 4 2 . .. . 4. -

Sample numbsr: A r,. I 1 ), ZL. io>-: Method deterrninz tion:

- Commts:

1 - PhRTlClILATE C1,EhNIII’ S I l ~ l : ~

---- nloisture total 5 9 , p p

Container numhw: 1. C - 4 2 . 3. 4

Sample number:

Method dcterniimit ion: Comcnts:

A I ,.! I;.:.,. i o r : I

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Sample box number.- / A i i i l i i c m l Ltm:lwr.iLuri.:

lmpinger 1120

Volume a f t e r sampling m m l Container No. c-3 Ether-chloroforni extraction

Impingcr prefil led w i t h 4 E r n l Extra No. - Volume collected a n i 1 I i ipinjyr \*.*.iter residue ! 4.2 I

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of’ in0ping:c.r iva t e r I

Impingers and luck half of Conh ine r No. - - f i l t e r . acetone wash:

/ ; ? I n h * ‘ I wtf Extra No. - Wright results n

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Dry probe and cyclone ca tcli: Container No.-

& I , , ~ i W ~ Ext-ri No. - h’eicht results n

Prohe. cyclone, fhsk. and Contilincr ~o.C-2 52 30.672 f r o n t hdf of f i l t e r . 5 2 , f S t O

Extra No. - Weight results I ! 3, n acetone wash: ..>a

Film number Container no. . .

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35.6 9n.3

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92.5 07.1

nc.6 93.3 96.1 9n.7

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00.4 91.3 94.0 96.5 90.9

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Sampl inq p o i n t numbcr on a diameter

1 2 3 4 5

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15 .....

16 . 17 ',

10 19

' 2 0 I' 21 .22 ' .

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6.7

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4.9 c.5 17.5 16.9

v..n x . 3 37.!; 52.5

71.7 7n.o t3.1 ?7,5 H.5 15.1 113.4

- 24 - 1.1 3.2 5.5 7.5 10.5 13.2 16.1 19.4 23.0 27.2 32.3 39.8 60.2 67.7 72.8 77.0 80.6

93.9 96.0 19.5 32.1 34.5 36.8 19.9

-