AP42 Section: 111.16

Reference:

Title:

12

Particulate Emission Sampling And Analysis, United States Gypsum Company, Environmental Instrument Systems, Inc., South Bend, IN, July 1973. Unpublished.

I I

11-D-12

GYPSUK MANUFACTURING /

Reference Number 1 2

AP-42 Section 8.

Code: 312/321-3770 101 South Wacker Drive/Chicago. Illinois 60606

L A. PURSEU Manager

Corporate Environmental h Energy Services

UNIZFDSZATES OypSuAl C O M M

PART1 CULATE EMISSION SAMPLING AND ANALYSIS

UNITED STATES GYPSUM COMPANY EAST CHICAGO, INDIANA

JULY - 1973

.-

SUBMITTED BY: ENVIRONMENTAL INSTRUMENT SYSTEMS, INC,

- 116 SOUTH

NORTH HILL STREET BEND, INDIANA 46617

I -

! TABLE OF CONTENTS

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i ' ,.. .

SECl'IO!:

1

I1

I11

I V

V

SUBJECT

INTRODUCTION

PROCEDURE

PROCESS AND SA-LING INFORMATION

RESULTS

DISCUSSION

PAGE

1

1

3

5

20

-

APPENDIX

A - PROCESS STATUS OF C W G E WEIGHT DATA

B - FIELD DATA SHEETS

C - LABORATORY DATA SHEETS

D - ALLOWABLE PIISSION RATES

E - FIGURE 1

...

~ . . . ..

I INTROWCTION

I . .

..- , ! .

Stack emissions t e s t i n g was conducted by Environmental Instrument

Systems, Inc. at t h e U.S. Gypsum Company, E a s t Chicago p l a n t t o de t e r -

mine p a r t i c u l a t e loading and emission r a t e s from se l ec t ed process duc t s

and con t ro l systems.

#Z Raymonds, 111 and ( 3 Kettles and the Dryer.

u l a t e sampling w a s a l s o conducted on t h e # 2 and #3 C o t t r e l l c o n t r o l

systems and t h e P e r l i t e Ore p rocess d u s t co l l ec t ion system t o determine

the ope ra t iona l e f f i c i e n c y of t h e i n d i v i d u a l u n i t s and t h e degree of com-

p l iance wi th a p p l i c a b l e a i r p o l l u t i o n con t ro l regula t ions . Sampling w a s '

conducted during t h e per iod of 6-18-73 t o 6-22-73 and r e l a t e d process

weight da t a was obtained from U.S. Gypsum personnel.

The s p e c i f i c process ducts sampled were the #1 and

I n l e t and exhaust p a r t i c -

I1 PROCEDURE

S a p l i n g Method

Sampling f o r p a r t i c u l a t e s u t i l i z e d the s tandard U.S. Environmental

P ro tec t ion Agency' (EPA) t r a i n (F igure 1). The' EPA t r a i n allows samples

t o be co l l ec t ed under i s o k i n e t i c cond i t ions . I n those i n s t a n c e s deemed

necessary a cyclone assembly was p laced ahead of the f i l t e r t o c o l l e c t

p a r t i c l e s g r e a t e r than 10 microns i n diameter.

eva lua t ions two complete sampling trains were used, one on t h e inlet t o

t h e con t ro l and t h e o t h e r on t h e o u t l e t of the cont ro l .

For t h e performance

Analy t ica l Procedure

Pre-dried ( a t 105OC) and pre-weighed glass f i b e r f i l t e rs w e r e used

f o r t h e c o l l e c t i o n of particulate matter.

run, the f i l t e r s were placed i n aluminum d i s h e s f o r t r a n s p o r t back t o t h e

Following t h e i s o k i n e t i c sampling

I . :

EIS l abora tory f o r ana lys i s .

and nozzle vas washed wi th acetone t o remove any ent ra ined p a r t i c u l a t e

ma t t e r ,

were c o l l e c t e d i n c lean , dry polye thylene b o t t l e s .

which were not removed wi th the ace tone were loosened by means of a

"rubber policeman" and placed i n t h e nozz le wash b o t t l e s .

I n a d d i t i o n , the i n t e r i o r of the probe

The cyclone assembly vas a l s o washed wi th acetone. These washings

Any adhered p a r t i c l e s

I n the l abora to ry , t h e f i l t e r and nozz le washings were t r a n s f e r r e d

t o s e p a r a t e t a r ed weighing d i s h e s , then oven d r i ed and des icca ted t o a

cons tan t weight .

balance.

f i l t e r weights and probe, nozzle and cyclone washing weights.

Resu l t s were recorded t o 0.1 mg us ing a s i n g l e pan

Total p a r t i c u l a t e weight then was determined as a sum of the

3

111 PROCESS 6 SAMPLING INFORIYITION

r I .

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The s p e c i f i c processes sampled from 6-18-73 t o 6-22-73 a r e

l i s t e d below.

I n l e t t o and o u t l e t from t h e 112 C o t t r e l l E l e c t r o s t a t i c P r e c i p i t a t o r

I n l e t t o and o u t l e t from t h e # 3 C o t t r e l l E l e c t r o s t a t i c P r e c i p i t a t o r

I n l e t t o and o u t l e t from t h e P e r l i t e Ore Expansion

0

0

process mul t ic lone system

0

0 Rock Dryer duc t

I1 and E2 Raymond M i l l d u c t s

6 1 and 8 3 K e t t l e Calc in ing d u c t s

Simultaneous i n l e t and o u t l e t sampling was coordinated by means of

hand c a r r i e d walk ie- ta lk ies .

sampling crew would n o t be o p e r a t i o n a l w h i l e t h e o t h e r crew w a s shu t

down dur ing change of sampling p o r t s .

a t i o n of c o n t r o l equipment e f f i c i e n c y w a s t hus t h e same f o r both i n l e t

a n d o u t l e t samples, i n a d d i t i o n t o be ing s imultaneous.

Coordinat ion of p l a n t process s t a t u s w i t h t h e sampling crews from

This method of sampling ensured t h a t one

T o t a l sampling t i m e f o r the evalu-

Environmental Instrument Systems, Inc. was performed by U . S . Gypsum 1 .

personnel . As i nd ica t ed by t h e Process S t a t u s and Charge Weight Data

1 I .

i

(Appendix A), a "communications breakdown" occured and t h e sampling of

t h e 62 Raymond Hill duc t , s p e c i f i c a l l y Runs 62 and 63 on 6-21-73, w a s

conducted dur ing a process i n t e r r u p t i o n . Run 6 1 w a s completed i n i t s

e n t i r e t y wh i l e t h e process w a s o p e r a t i o n a l .

I n l e t sampling t o t h e 63 C o t t r e l l E l e c t r o s t a t i c P r e c i p i t a t o r

n e c e s s i t a t e d the use of a s t anda rd p i t o t tube f o r v e l o c i t y head de te r -

minat ions. Veloc i ty p re s su res lower than 0 . 1 inches of water were

experienced i n a l l t h e sampling p o r t s .

4

!

I . r:

Uee of a s tandard p i t o t tube i n p l a c e of the S-type allowed accura t e

measurement of low v e l o c i t y p re s su res t o be made.

Some d i f f i c u l t y was i n i t i a l l y experienced i n the sampling of the

K e t t l e Calcining duc t s .

equipment clogging were encountered. S p e c i f i c a l l y , the 4" f i l t e r , and t h e

probe and the nozzle tended to c log w e l l before t h e end of t h e 110 minute

sampling per iod. This problem w a s overcome by having on hand e x t r a f i l ters ,

assembled In t h e f i l t e r suppor t s , f o r a quick change of a clogged f i l t e r and

the use of exceedingly h igh probe temperatures t o prevent moisture-induced

clogging of t h e probe and nozzle.

P a r t i c u l a t e flow r a t e s which induced sampling

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

IV RESULTS

I .. , I

1-

5

The following s e c t i o n p r e s e n t s the r e s u l t s of the sampling

conducted a t t h e U.S. Gypsum Co., E a s t Chicago, Indiana p l a n t .

Calcu la t ions of t h e Allowable Emission Rate ( l b s / h r ) were

made by using the equat ions o u t l i n e d i n Appendix D.

charge weights of va r ious processes were used i n those cases

where more than one process was as soc ia t ed w i t h a p a r t i c u l a r

con t ro l system.

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. . !

,- ! L .

I ' I

V DISCUSSION

Sampling of the 1/2 and #3 C o t t r e l l E l e c t r o s t a t i c P r e c i p i t a t o r s

and the P e r l i t e Ore Expansion process mult ic lone system allowed t h e

determinat ion of W o important parameters . These parameters a r e the

p a r t i c u l a t e emission r a t e s and the percent e f f i c i e n c y of t h e e x i s t i n g

con t ro l systems.

Table 1 summarizes the emission r a t e s determined i n t h e f i e l d and

the app l i cab le allowable en i s s ion r a t e s as ca lcu la t ed frw t h e "Municipal

Code of East Chicago, Indiana Rela t ing t o A i r Qual i ty Control" (Appendix

D). Table 2 presen t s t h e percent e f f i c i e n c y of t h e e x i s t i n g c o n t r o l

systems.

TABLE 1. MISSION RATES / ALLOWABLE MISSION RATES

Stack Emission Rates ( l b s / h r ) Allowable Emission Descr ip t ion Rate ( lb s /h r )

Run 3 - Run 1 Run 2

# 2 C o t t r e l l 2 60 353 658 37 .2

#3 C o t t r e l l 15 3 . 0 3 . 6 28.4 (Run 1 - 28.7)

P e r l i t e Nul t ic lone 6 . 8 3 . 9 3 . 8 4 . 1

TABLE 2 . PERCEh'T EFFICIENCY CONTROL EWIPMENT

Stack % Eff i c i ency

Run 2 Descript ion

- Run 1

# 2 C o t t r e l l 95.58 95 .53

#3 C o t t r e l l 98.88 9 9 . 8 1

P e r l i t e Multiclone 33.33 30 .76

Run 3

91.99

99.79

35.25

. . . . *

21

Table 1 i n d i c a t e s t h a t the p a r t i c u l a t e emission r a t e s from the

C2 C o t t r e l l ' E l e c t r o s t a t i c P r e c i p i t a t o r increased s u b s t a n t i a l l y from

t h e f i r s t sampling r u n on 6-18-73 (Monday) t o t h e t h i r d sampling run

on 6-20-73 (Wednesday). The process r a t e s remained the same during

. the t h r e e sampling runs. Taking i n t o cons idera t ion the p a r t i c u l a t e

weight loading t o the p r e c i p i t a t o r , Table 2 shows t h a t t h e percent

e f f i c i e n c y of the system remained e s s e n t i a l l y cons t an t a t about 95.5%

on Monday and Tuesday, then decreased t o 92% on Wednesday. I t i s

r e a l i z e d t h a t the f i r s t two s a m p l i a g runs (Monday and Tuesday) on t h e

o u t l e t s i d e o f t h e p r e c i p i t a t o r were performed a t lower i s o k i n e r i c con-

d i t i o n s than the f i n a l run on 6-20-73 (Wednesday). The lower i s o -

k i n e t i c i t y f a c t o r i n d i c a t e s t h a t t h e p a r t i c u l a t e f l m r a t e t h ru the

probe nozz le , a t the time of sampling, w a s b i a sed toward a h ighe r

mass concent ra t ion than w a s a c t u a l l y p re sen t i n the s t a c k gas stream.

This would i n d i c a t e t h a t the percent e f f i c i e n c y on Monday and Tuesday

. w a s probably s l i g h t l y h igher than the 95.5% observed. A l l t h r e e sampling

runs i n d i c a t e t h a t the p a r t i c u l a t e emission r a t e from the 112 C o t t r e l l

exceeded t h e a l lowable emission r a t e as s e t f o r t h by the "Municipal

Code of E a s t Chicago, Indiana Rela t ing t o Air Q u a l i t y Control."

The 6 3 C o t t r e l l E l e c t r o s t a t i c P r e c i p i t a t o r w a s found t o be i n

compliance wi th the appl icable a i r p o l l u t i o n c o n t r o l r egu la t ion on a l l

t h r e e sampling runs.

two sampling m n s , whi le the f i r s t m n showed a 98.88% e f f i c i e n c y (see

Table 2 ) . The second and th i rd sampling runs were performed wi th only the

Stucco Conveying process i n opera t ion . During a p o r t i o n of t h e f i r s t

sampling run, both the Stucco Conveying and t h e Tube Mi l l i ng processes

were o p e r a t i o n a l ( see Table 1 and Appendix A).

The p r e c i p i t a t o r exceeded 99% e f f i c i e n c y on the l a s t

. .

, . .

~

! :

.. .

- . L ~~

!

I

I .

i :

Results of emission r a t e sampling f o r the P e r l i t e Ore Expansion

process mult ic lone system i n d i c a t e t h a t t h e al lowable emission r a t e

was exceeded only during the first sampling run (see Table 1). It is

f e l t t h a t the first run is not i n d i c a t i v e of normal process opera t ing

condi t ions. On 6-22-73 (F r iday ) , t h e day of the P e r l i t e mul t ic lone

sa-=l ing ope ra t ion , e l e c t r i c a l d i f f i c u l t i e s were being experienced by

U.S: Gypsum personnel i n t h e opera t ion of the P e r l i t e system.

ing r e so lu t ion of the problems, and when informed t h a t t h e P e r l i t e

system was aga in

performed the f i r s t of t h e t h r e e s a p l i n g runs. The raw f i e l d d a t a

then obtained from t h e nex t two mns, when compared with the f i r s t ,

indicated t h a t the P e r l i t e process might not have been completely

Follow-

31 opera t iona l , " Enviro.menta1 Instrument Systems, Inc .

operat ional" during t h e f i r s t run. S p e c i f i c a l l y , p i t o t tube v e l o c i t y I,

pressure readings f o r t h e I n l e t duct t o t h e P e r l i t e mul t ic lone system

were s u b s t a n t i a l l y lower dur ing the f i r s t run than those experienced

on the f i n a l two runs. All t h r e e runs showed t h a t the mul t ic lone system

w a s opera t ing a t a 30-35% e f f i c i e n c y (Table 2 ) .

. , . . I . ,

. I'

APPENDIX

TO : Technical Services Fi le

FROM : Michael Maillard,' P .E .

SUBJECT: Source Testing 'Conducted a t U.S. Gypsum io. , 10090 I.1. .ki?..-son. 2iVer ii.ouge

Par t icu la te tes ts 'were conducted on Xay 14, 1975, a t the &:we ioc i t ion

on the gas-fired chemical ki ln-ket t le . system controlled by a Flex-Kleeh b. f nouse.

The tests ,weye /chnducted by the Technical Services section of the L'33 .ie Cca.ty Air ', 1

Pollution C o n t h l Division. -Monitoring of the processes was conducred by ir. Goyd

w i t h stack opacity evaluation performed by Nr. Guldoor. - both of t h e Znforceaent

section.

i

The emission tests average 3.16 .1bs/l000 l b s exhaust. gas. The C 'c:,:aile

emission is 0.20 lbs/lOOO.lbs exhaust gas.

Preliminary data were obtained on May 6 , 1975. T h i s invc'ved ve io t ' t y

head ranges, s tack temperatures, f l u e gas, analyses, and moisture content d z t e r -

mination. Three par t icu la te samples wwe obtainsa on May 14, 1975, from t h e 26''

1.0. stack by sampling a t 8 points across each of two perpend<cular diamte:. ii,

the sampling plane, a t 4 minutes per p o i n t . The sampling t r a in used (see af . .-'.ed

sketch was sequentially: 'nozzle f o r appropriate i sokine t ic sampling r a t e s . -0 -

l e s s s t ee l f i l t e r holder w i t h a meshed g la s s th imble (sample $1). o r a 47 G::: ,:lass

fiber f i l t e r (samples H2' and 813); two standard lmpingers i n paralie: w i t h i n t r i a l

100 ml d i s t i l l e d water per impinger; condenser; l-l/Z c fc ;eakleass pump; and dry

gas meter with o r i f i c e meter. Velocity t raverses were taken pr lor t o each s w i e

w l t h the probe washe6 obtafned 4n tlia f l 6 l d .

i

. .

' I

I ,

. . U.S. Gypsum Company - Source Testing ' June 6,,1975 U.S. Gypsum Company - Source Testing June 6,,1975 . .. .-

t

The processing dur ing the sampling was -. 55 tons/hr o f gypsum rock

t o the k i l n , 4 tons/hr of this product was siphoned off f o r s o i l conditioner

use and the balance sent i n t o three 19 t o n / h r capacity ke t t l e s . . Y '.

The opnclty evolwttlons o r c ' l i s t c d i n Tnl l l t? I . I t slloultl I I P notctl

I : I I ~ I , 1 . 1 ~ 27itiitiitt;n' viitint,Ioti wnq trnllqoii 11.y nrjUttllsnc.ntolI ttinlnt.tnt 111 1 1 1 0 tint I:

breaking o f f .

material will cause build-ups and incidents of this kind.

The uninsulated stack coupled by the hygroscopic nature of the

.I

The sampling r a t e was found t o be 107%,.104%, and 97% of proper

i sokine t ic flows f o r t he three samples, respectively. The following data

sumary sheet contains sampling parameters and the. resu l tan t emissions.

a t t . - 3 .

copies: Messrs. C. Andrus (Mr. Mdin) B. Baskin

, . - .

- . .

. . . ,

. . . ., . ". .' - i l I.

0 10

0

Sourcc Sariipl i n g - U. S. Gypsuia Co. Junc 6, 1375

20 30 j 40 : 5G

14-75 9:05-10:15 Particulate. ' 9:30-10:18

14-75 . I 10:53-12:lO Particulate . 11:30-12:15 15

14-75 2.:00-3:20 Particulate 2 :05-3:40 28

48

!

j 2 ! i 28

f ' I I

i I 68 i

~ ~~

Total observed minutes i n violat ion = 2 Minutes i n violat ion during tes t ing = 2

..

.f I

1 . ..

WAYNE COUNNDEPARTMEKT OF HEALTH, AIR POLLUTION CONTROL DIVIS1O:I . - .. . I

e , . . . .> * _ SUELWRY OF STACK S/LVSLING DATA AND TEST RESULTS .

.NIPElENT AND CONTROLS: Chemical. Kiln Pr Kettles Control 1 vd htt F1cx-i(l*on L I Q : ~ : ~

, corrcctcd t o 502 excess a ir I4 '

NATION: 10090 II. Jeffcrsan. R i v p r Rot1 on - H. S . G V P S I I ~ CO. TEST DATE: :',iv 1 4 . 197L

TACK DIMENSION: 315" I . D . STACK AREA: 7.069 Sq. Ft. PERMIT do. 31 88

.

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

&. Don Henry, Esquire U. S. Environmental Protection Agency, Region LX 103 California Street San ~rancisco, California 94111

Y o u r Code: FXT-242-18

Dear Mr. Henry:

This is t o advise that the completion date fo r dust co1lectir.g equipuent now being installed on our #3 ket t le I s W c h 30th.

Copies of Source Test plan covering the installation particulars and test procedures have been c o e e t e d and submitted with this l e t t e r and t o the Washoe C o u n t y District Health Department.

In order t o finalize testing and bring thls ket t le on stream at the earliest possible date we would like t o proceed with testing immediately after the installation is completed or amund Aprin 4th.

I sincerely hope that t h i s wlll meet Vith yuur approwl.

Very tnrly wurs, UNITED SPATES GYFStM C W A R Y

j&?zuLL L. A. Zlech Works Y ! r

LAZ: 68

UNITED S T A T E S GYPSUM COMPANY

March 24, 19n .-

Washoe County M s t r i c t Health Department Mvlsion of Envlrommtal Services P. 0. Box l l l 3 0 Reno, Nevada 89510

Attention: Mr. Charles R. Breese Jr., Mrec to r

Dear Mr. Breese:

Please f ind the enclosed source test plan to cover the r e - a c t i n t i o n of #3 and #4 gypsum k e t t l e s which were shut down =der your direc- t ion on May 31, 1976 because of the lack of emission control devices. A s you h w we are presently operating #1 and #2 ke t t l e s v l t h ade- quately designed bagnouses *ich e f fec t ive ly r-e par t icu la te emis- sion from the stack effluent. dewnstrated by source sampling performed under the d i rec t ion of ob- servers fraa your d e m n t .

Resent narket demand f o r gypsum products necessi ta tes act ivat ing a th i rd k e t t l e and a stand-by k e t t l e i n order t o prevent l o s s of busi- ness due t o mechanical breakdown. engineering depsrtnr?nt has designed a dust col lect ion system that w i l l u t i l i ze a single baghouse co l lec tor shared by both #3 ar.d #b ket t les . ating on #2 ke t t l e . adequate f o r one k e t t l e only and the e l e c t r i c a l control c b c u i t r y fo r the new col lector e f fec t ive ly prevents #3 and #4 ke t t l e s from operating a t the same time. A set of pr in t s for the in s t a l l a t ion is enclosed for your reviev.

The Source Test Plan included v i t h t h i s report follows the outline you submitted to us wlth your l e t t e r dated 3-4-77.

It i s noted that i n the period during which we are mobilized v i t h equipuent and technical help t o do source sampling we intend to retest the clean air effluent from t h e e m d e d p e r l i t e col lector . YOU w l l l r e c a l l t h a t source sampling conducted during 2ecember 1975 rwealed excessive par t iculate emission from t h i s stack. A new c lo th specification vas developed imrediately f o r t h i s col lector , ne%- bags were installed and m i c u l a t e emission vas effect ively reduced.

Effective m i c u l a t e r emna l was

In order t o accomplish t h i s our

The baghouse i t s e l f i s very similar to the one now oper- The capacity of t he new baghouse co l lec tor i s

I

Due t o the lack of t ra ined manpover, h-r, t h i s source has not ye t been retested. - ..

c It is also noted t h a t . t h e same people vho conducted the source sampling during pr ior t e s t i n g are awihb le - tQ us again eo t h a t ve can assure an adequate degree ol t echnica l competence during the present program.

If you have questions or need further inior&tion do not hes i ta te t o c a l l upon us.

V e r y s incerely yours,

UNITED STATES GYPSUM COMPANY

L. A. Ziech Works Manager

.:

i

I

- TEXT - - - KETTLE MILL OPERATION FOR (IUALIPI A N D EFFICIENCY

r l -

Masonry

Refractory

Burner

. .

FIGURE 9

10-76

-

Combustion chamber

' The continuous CalCjning kenle. ~ u c c o is discharged.conrinuously by introducing into an overflow channel Inside (solid arrows). Hear flows from the firebox. around baffles, lhrough rhe flues and out the stack (broken arrowsl.

a;r

. .

16

i ! i i

,, . 1 i i

1 I 1 ST-7-41 37- 1

_. .. .. t i

TEXT KEnLE MILL OPERATION FOR QUALITY AND EFFICIENCY ____ _-- -

Cyclone 1

'0-76 9 ST-7-4137- 1

, ./ ' .. . . . , . . .. I

!i ?

. . . . .

..'? . . . ,; j: Report No. 23074 : I. . . . . . . . .... .... . . . . . . . . 'Pile No. 1-0015 ;..

. . , . 8 .

_ . . . - . ..;I . .

. . . . . . . . 1/78/76 *:

. . . . - . . - ..

.........

-- :.;.. -5- - . . .

. . . .. ;;;: < . .? b,

.c

. .

... . . . . .

:. , . : ..

' - . . ,!.f .. I . \ ,' .*

. .

.... _- - .- _. . < . . -:. i'=.

7 - , . .

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

...... . . . . . . . . . . - z . . . . - . :.. . . . . . . . . . . . . . . . . . :. ..T : - . . . .

t . . . :-. -. -

. . ' I .

. . ._. - . . . .,* . i', . . . . .

. - _ - . .

; :.. .- I

. . . ..

.. . . . . . .

. . . . . . . - < . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .r . . . . . . . . . . .

' . , .? ,-

. . . . .

. .

. . . -

...

REPORT

. . . . . . . . .

- .

. .

. . . . . .

. .

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

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

. ,

. . . . ~.

. . . :

.. : . . . . . . '.

. . - - . . . I--faolj?etic S o v c e ,sampling: Empire ..~ypstrm Mill -.+

.. . . ~- - _ , . .P.er Mr. G. W. Xellogg's,request, i sok ine t i c tests were performed on -

. .I ::all eleven s tack emission souzces a t the Enpire gypsum mill i n accor-

: dance w i t h the guidelines spec i f ied by the District Board of Health .. -i . . . -. ';-isof Nashoe County, Nevada. .. - 3

. - - .. .. siCcciity observers were present f o r 'the i n i t i a l t e s t i n g t o judge whether

.we were qual i f ied t o p e r f c h the tests ourselves. The observers w e r e satisfied with our performance and w e r e w i l l i ng t o accept our data .. -

' . , . i . .

.t . . -:--without an observer. present. . .

zz%e- r e su l t s . a=e: . .: . .>

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

. - . . - - -

. . . . . . . . -i - - - . . . . ' Pollut ion Mass Rate, Us/. ' .Concentration,grains/

. h r SCF ..: 0.0020 ..: 0.053

Raymond Mill NO. 3

Kettle No. 1 .: 3.43 . 0.116 ~<

3 , . ' 0 .OO 30 0.015. .?

f Packer No. 1 and 2 0.14.

0.0048 - _ Packer No. 3 . ' 0 106

0.0003 '0.0025

. . Process

j . . . . . ... i 7 - . . . .<: .I

- . . 0.0031 . . . . -pond M i l l N o . 4 0.110

0.194

.. Rock Screen D u s t Collector : 0.062

' ' 0.075.

' . 0.0154.

.. 2.99 ; . Kettle No. 2 .

. .? . . - . ' 0.0060 ;i . . .

5 .:5

. .

0.0009 . . . .

. .

End. Finishing Saw !rube M i l l Stucco Screen

. ,

p e r l i t e .. 13.55 . . . . . 1-28 - 1 . . . . . .

'J -

emission sources w e r i ' w e i w i t h i n the compliance levels, except f o r

A p a r t i c l e . . s i z e analysis

j

! the per l i t e . .A hole w a s found i n a co l l ec t ion bag, which should account

was performed on the sample co l lec ted .by the f i l ter , ~ O T the .h ign amount of pa r t i cu la t e col lected.

+ e t e s u l t s are: 1 - 525 Mesh 20. Microns 91.74% Finer than i

- 7'4.25- 33 99;12 . . - L .325 .- .-2 L:. 45 .: 99.99 - . 200-.-- - , , 75 100 .oo - - - - - : - . which indicate t h a t perha s a 'c!!ange i n bag mater ia l is required. - - further t e s t ing , howeverf?V.ill be necessary to, ve r i fy it. - - _ - - - - - . _ .

. . . -c ..

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

. . ., . . i _ .

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

. . .

. . . -

....... . .

No. C i a zib.~ve ems;;,--. 10 , . No. Dla 3elsw c m s t . - . .

. . . . . . . . . ....... . . . . . ~. ... . : . . . . ; . , .- . . ..; .. . ; . . :

. . -

. . . .

. .

. . . -

_ .

I

. . . . . .

. .

r . .. , . .

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

. . . .

. .

. .

- -. March 25, 1977

-. Source' Test 'Plan

1. Source Information:

A. Name, address, and location of the f a c i l i t y being tested:

United S ta tes Gypsum Company Empf re, Nevada 89405

The Empire f a c i l i t y is located on S t a t e Highway 34, approx. 100 miles north of Reno, Nevada.

Responsible persons a t the f ac i l i t y , and t e l ephone number: 8.

Mr. L. A. Zlech, Works Manager, Ext. 25 Est. 36

Mr. D. L. Mustard, Personnel S u p t . , Mr. K. V. Kraft, Engr. Supt., Mr. E. 0. Heiss, Project E n g r . , , . Ext. 36

Mr. E. C. Dessain, Chemical Analyst and graduate of the E.P.A. course In Source Sampling will be assigned t o Empire d u r i n g source testing from the U.S. Gypsum Co. Research Center, 1000 E. North- west Highway, Des Plaines , I l l .

(702) 557-2341 II

. I1

' : n . .

60016, phone (312) 299-3381.

2. Testing ' F h Informatfon: . .

A. : Name and address of the finn conducting the testing.

Due t o the prohibi t ive expense of h i r i n g an outside consultant f o r work a t t h i s i so la ted . loca t ion , no testing firm will be involved i n this Source Test Plan. All work will be performed by U.A. Gypsum

, . Co. employees under the supervision of E.P.A. f ie ld observers.

Responsible person a t the testing firm, and telephone nmber. B.

Not applicable t o this Source Test Plan.

3. Sanipling Equipment:

A. - A description o f the emission sampling equipment including a schematfc diagram of the sampling t r a i n .

Is0 Klnetic s tack sampling tes t will be performed by Mr. Oessain and Mr. Heiss on #3 Kett le , 114 Kettle and on t he perlite expander. The Research Appliance Corporation sampler will be employed - the schematic diagram o f the sampling t r a i n for t h i s device is shown on p. 581, Chapter 1 - E.P.A., app. A. attached f o r your review.

A copy o f this page is

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' .. -. . . ; - - . . 4. Procedures: .~ .. * .

A. 'Types of pollutants t o be sampi"ed:

Par t icu la te emissions w i l l ' b e measured and the PMR (Pollution .Mass Rate in lbs . /h r . ) and the C (Concentration i n grains/SCF)

. . . . will be determined. Stack moisture will also be determined.

B. A description of the sampling analysis procedures:

A preliminary survey of each stack wfll be made i n order t o determine cross-sectional a rea , gas veloci ty , temperature, e tc . so t h a t the R.A.C. can be f i t t e d w i t h the proper nozzle before i t i s transported t o the sampling s i t e . The stack will be traversed i n the manner s e t o u t i n Chapter 1 - E.P .A . and f i e l d notes and calculat ions will be submitted t o your o f f i ce on the same forms as the da ta and report of 1-28-76, report $23074, f i l e no. 1-0015.

C. Documentation for any proposed var ia t ions from the specif ied procedures:

source test. '*There will be no v a r i a t i o n from specified procedures d u r i n g t h i s

5. Emission Point Information:

A. A s'ketch w i t h dimensions indicating the flow of exhaust gases from the process through the control equipment and associated d u c t work t o the stack.

A complete s e t of prints of the new i n s t a l l a t i o n has been provided for your review - these will provide s u f f i c i e n t dimensional information In order t o provide be t t e r visul izat ion of the exhaust gas and d u s t flow, a small schematic sketch has a l so been included f o r your review. . .

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B. A diagram of the stack showjng the.dimensions and the ionfiguration of the sampling, and the d i s t ances ' t o the nearest u p stream and down stresm flow interferences.

(Sketch inciuded w i t h this report)

C. A cross sectional sketch o f the s tack a t the sampling.location. showing sampling p o i n t locations.

(Sketch included w i t h t h i s report)

Estimated f lue gas conditions a t the sampling location,, including temperature, moisture content and velocity.

Avg. stack temperature, 300' F., moisture content var ies between 7 to 10%. avg. gas velocity ( S t d . ) 29 F.P.S.

-6. Prccess Equipment:

A . . A description of the prccess operation, including a process flow sheet.

Ground raw gypsum is fed in to the Kettle which i s heated by fuel o i l . shel l and t h r o u g h heat exchanger f lues t h a t pass through the agi.tated ground gypsum. The combustlon gases pass in t c t he m a i n stack. As combined moisture i s removed from the gypsum, i t passes through the steam stack in to the d u s t co l lec tor which returns the

. . d u s t t o the Kettle. The clean e f f luen t from the co l lec tor passes . t o the main stack.

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The heated gases from the furnace pzss around the suspended

(Typical Kettle cross section attached t o this report . 1

Type and quanity cf raw mater ia ls , ca t a lys t s and products being used or produced i n the process.

Approximately 20 tons of raw ground gypsum a r e charged intc the Kettle. When the batch i s completed approx. 16 tons of calcined gypsum i s produced t h a t will be used i n making p las te r products. If the batch Kettle is used t o produce calcined gypsun for wall board products a small smoun: (10 t o 20 lbs . ) of dry calcium chlor- ide i s added t o speed up the removal of corbined moisture.

C. Maximum rated capacity of t h e process.

X3 Kettle capable of producing 7.0 to.ns per hour. t ons per hour.

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* - D. Actual maximum operating capacity of .the process. . . - .. During 1977, e i the r f 3 or 84 Kgttles will -6roduce appiox. E.5 tons per hour. These two Kettles cannot operate a t the same time.

E. Operating capacity during the previous six month period.

Zero.

F. Process data t o be monitored t o insure represent i t ive operation during the t e s t .

All data shown on the attached data summary sheet will be moni- tored to insure representative sampling.

Normal maintenance schedule for t h i s process.

Both # 3 and #4 Kettles have been s h u t down since 5-31-76.

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Kettles are usually s h u t down Sunday and Eloriday f o r maintenance.

Type of feed stock or fuel t h a t causes the g r e a t i s t inl ividual emissions and the percent of annual production for whfch these materials are used.

Ground gypsum is the primary source of par t icu la te emissions and moisture and accounts for 90% o f the t o m i znnual prcduction. Combusticn prcducts are a lso released OUT concentrations are low due t o the la rae d i lu t ion ~y secondary a i r . corbustion smoke i s produced. The major v i s ib le emission from the Kettle stacks is moisture (steam) which is v i s ib l e during cold weether.

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7. Control Equipment:

A. Description of emission control system including the types of control equipment, manufacturer, ra ted capacity.

A complete s e t o f pr ints and a. Bill of Material i s included which describes the Flex-Kleen baghouse co l lec tor i n d e t a i l .

e. Data t o be monitored and recorded t o insure representive operation o f the control equipment dur ing testing.

The Kettle operator will monitor c r i t i c a l d a t a d u r i n g the t e c t as he does d u r i n g nornzl operation. The following data can be taken from the autonatic recorder char ts : stucco te r re ra ture , stack tenperature, time and curve o f t he Kettle "cook of f" cycle.

flow r a t e s , pressure drops , temperature, and voltage of e l ec t r i ca l input.

C. Minimum acceptable values of a l l control divice parameters, sucn as

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- A f ina l b a t c h dump t'emperature of 27Go F. tcr 300° F.-and a cycle time between 1 hr. 45 mins. t o 2 firs. will be requirec t c dupl'cate normal cperation.

D. Description o f any conditioning of gases p'iior t o the control device.

A mixture of a i r , gypsum pa r t i c l e s and steam passes in to the Cag- house col lector . No gases a re produced during calcjnation ana no gas conditioning i s required.

E. Normal maintenance schedule on control equipment f o r previous year.

This i s new equipnent and has n o t been previously mzinta'ned. Based on the maintenance his tory of Y2 Kettle dust co l l ec t c r , the following schedule will be applicable: 1. Visually inspect s tack e f f luent t a i l y . 2. Inspect i n t e r i o r of co l l ec t c r week;.^ o r b i - weekly for t o r n o r loose Dags. 3. Purchase a n d ins ta ' l new tags as necessary.

8. Data Sheets:

f i . Copies of f i e ld d a t a sheets t o be used dur ing the test . I

(copies enclosed.)

5 . Chain of Custody:

A. A description o f the procedures tha t wil l be fo l loce i t o ca in ta in the i n t e ~ r i t y of the samples col lected.

There are oniy two co l lec tor boxes for the R.A.C. sampler. the cornpleticn of the t e s t r u n , the box will be 13beie.i and t rans- ported t o the plant labcratory for sample weighin: and calculat icns . Ordinarily the f ina l data and calculat icns will be cocpleted on the day fcllcwing the test,

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B. Copies of chain of custody sea l s and data sheets:

Custody sea ls have n o t been used d u r i n g previous t e s t i q . necessary, however, we will s e t u p a custody seal systerr accordinq t c your recomnendations.

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19. Qual i t y Control : j The following items si-,ould be avai lable t o the observer c 4 G r t o the s t a r ? of the t e s t .

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A. Calibration sheets for d r y gas meter, p i t o t tube, nozzle a r ~ !)?.her equipfient t ha t requires ca l ibra t ion .

Qual i ty assurance control char ts f o r the anaTytical procejljres t o be used in the analysis of tes t samples.

A l i s t o f preweighed f i l t e r s to .be used durins par t icu la te emissicn

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