AP42 Section:

Reference: Title:

12.2

2 Source Testing of a Stationary Coke- Side Enclosure: Burns Harbor Plant, Bethlehem Steel Corporation, Chesterton, IN, EPA- 340/1-76-012, U. S. Environmental Protection Agency, Washington, DC, May 1977.

EPA-340/1-76-012

$k- May ,1977, Stationary Sou rce Enforcement Series

SOURCE TESTING OF A STATIONARY

1 COKE-SIDE I ENCLOSURE I

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BURNS HARBOR PLANT BETHLEHEM STEEL CORPORATION CHESTERTON, INDIANA

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U.S. ENVIRONMENTAL PROTECTION AGENCY OFFICE OF ENFORCEMENT OFFICE OF GENERAL ENFORCEMENT WASHINGTON, D.C. 20460

U N I T E D S T A T E S E N V I R O N M E N T A L P R O T E C T I O N A G E N C Y WASHINGTON. D C. 20460

..- OFFICE OF ENFORCEM/IEIlT

MEMORANDUN

S u b j e c t : T r a n s m i t t a l of Volume I of DSSE’s R e p o r t “ S o u r c e T e s t i n g o f a S t a t i o n a r y Coke-Side E n c l o s u r e ”

To: S e e D i s t r i b u t i o n

A t t a c h e d i s a copy of t h e s u b j e c t r e p o r t . T h i s volume c o n t a i n s a l l o f t h e d i s c u s s i o n , c o n c l u s i o n s and summaries of a l l of t h e r e s u l t s of o u r e x t e n s i v e t e s t i n g p r o g r a m a t t h e B u r n s E a r b o r c o k e - s i d e s h e d ( B e t h l e h f m S t e e l C o r p o r a t i o n , C h e s t e r t o n , I n d i a n a ) , March 3-7, 1 9 7 5 . The r e m a i n i n g e l e v e n vo lumes oE t h e r e p o r t c o n t a i n s p e c i f i c t e s t m e t h o d o l o g y , t e s t and p r o c e s s d a t a . B e c a u s e t h e y a re so v o l u m i n o u s , w e h a v e l i m i t e d t h e i r d i s t r i b u t i o n t o ESED and DSSE.

DO n o t h e s i t a t e t o c o n t a c t L o u i s P a l e y (202-755-8137) of my s t a f f f o r any

Attac hmen t

cc: S t a t e and L o c a l A g e n c i e s ( S e e A t t a c h e d L i s t )

EPA L i b r a r i e s NTIS EPA R e g i o n a l C o n t a c t s

Howard Bergrnan Dave Brooman Ken Eng Lew F e l l e i s e n Donald Goodwin L o i s Green Geof f Grubbs R o b e r t H e n d r i c k s J o h n Hepo la Mark Iiooper Re id I v e r s o n L a r r y J o n e s Dave Kee Pete K e l l y L a r r y K e r t c h e r F r e j L o n g e n b e r g e r Lee M a r s h a l l Gary McCutchen Bruce b l i l l e r Walter Mugden Roy N e u l i c h t Gary P a r r i s h Norman P l a k s S t e v e R o t h b l a t t B e n S t o n e l a k e Andrew Tr enholm David z l l r i c h Lance V i n s o n Thomas V o l t a g g i o R i c h a r d Watman James W i l b u r n G a ’ l e I v r i g h t Gary Young

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DISTRIBUTION

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ATTACHED LIST

D i r e c t o r , N e w York - D e p a r t m e n t o f E n v i r o n m e n t a l

D i r e c t o r , P e n n s y l v a n i a - D e p a r t m e n t o f E n v i r o n m e n t a l

D i r e c t o r , P e n n s y l v a n i a - A l l e g h e n y Coun ty B u r e a u

D i r e c t o r , P la ry land - S t a t e Degmrtment of H e a l t h and

D i r e c t o r , Piest V i r g i n i a - A i r P o l l u t i o n C o n t r o l Commission D i r e c t o r , Alabama - S t a t e D e p a r t m e n t o f P u b l i c H e a l t h D i r e c t o r , Alabama - J e f f e r s o n Coun ty H e a l t h D e p a r t m e n t D i r e c t o r , Ken tucky - A i r P o l l u t i o n C o n t r o l Commission D i r e c t o r , T e n n e s s e e - C h a t t a n o o g a - H a m i l t o n Coun ty

D i r e c t o r , I l l i n o i s - E n v i r o n m e n t a l P r o t e c t i o n Agency D i r e c t o r , I l l i n o i s - C h i c a g o - D e p a r t m e n t o f E n v i r o n m e n t a l

D i r e c t o r , I n d i a n a - S t a t e Board of H e a l t h D i r e c t o r , I n d i a n a - D e p a r t m e n t o f A i r Q u a l t y C o n t r o l D i r e c t o r , M i c h i g a n - D e p a r t m e n t o f N a t u r a l R e s o u r c e s D i r e c t o r , ? . i i ch igan - Xayne Coun ty H e a l t h D e p a r t m e n t D i r e c t o r , P l i n n e s o t a - P o l l u t i o n C o n t r o l Agency D i r e c t o r , O h i o - E n v i r o n n e n t a l P r o t e c t i o n Agency D i r e c t o r , Oh io - D e p a r t m e n t o f P u b l i c H e a l t h and W e l f a r e D i r e c t o r , Oh io - A i r P o l l u t i o n C o n t r o l D i v i s i o n D i r e c t o r , O h i o - P o l l u t i o n C o n t r o l Agency D i r e c t o r , O h i o - P o r t s m i t h C i t y H e a l t h D i s t r i c t D i r e c t o r , Oh io - Mahoning-Trumbull A i r P o l l u t i o n Agency D i r e c t o r , W i s c o n s i n - D e p a r t m e n t o f N a t u r a l R e s o u r c e s D i r e c t o r , T e x a s - S t a t e D e p a r t m e n t of t i e a l t h D i r e c t o r , T e x a s - D e p a r t m e n t of P u b l i c H e a l t h D i r e c t o r , P l i ssour i - A i r C o n s e r v a t i o n Commission D i r e c t o r , b : issouri - S t . L o u i s - D i v i s i o n o f A i r p o l l u t i o n

D i r e c t o r , C o l o r a d o - D e p a r t m e n t o f H e a l t h D i r e c t o r , C o l o r a d o - A t t o r n e y G e n e r a l ' s O f f i c e D i r e c t o r , U tah - S t a t e D i v i s i o n o f H e a l t h D i r e c t o r , C a l i f o r n i a - A i r R e s o u r c e s Board D i r e c t o r , C a l i f o r n i a - San B e r n a r d i n o ' C o u n t y A i r P o l l u t i o n

C o n s e r v a t i o n

R e s o u r c e s

o f A i r P o l l u t i o n

iviental Hyg iene

A i r P o l l u t i o n C o n t r o l Bureau

C o n t r o l

C o n t r o l

C o n t r o l D i s t r i c t

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ACKNOWLEDGEMENTS

T h i s r e p o r t was p r e p a r e d u n d e r t h e d i r e c t i o n o f M r . John M u t c h l e r w i t h t h e a s s i s t a n c e o f p r i n c i p a l a u t h o r s Thomas Loch, R i c h a r d P o w a l s , and J a n e t V e c c h i o o f C l a y t o n E n v i r o n m e n t a l C o n s u l t a n t s , I n c . The P r o j e c t O f f i c e r f o r t h e U.S. E n v i r o n m e n t a l P r o t e c t i o n Agency was M r . Louis P a l e y . The a u t h o r s a r e g r a t e f u l t o M r . P a l e y f o r h i s r e c o m m e n d a t i o n s , comments , and r e v i e w t h r o u g h o u t t h e e x e c u t i o n and r e p o r t d e v e l o p m e n t p h a s e s of t h e s t u d y . The a u t h o r s a l s o a p p r e c i a t e t h e v a l u a b l e c o n t r i b u t i o n s of Mark A n t e l l , Be rna rd Bloom, and K i r k F o s t e r ( D i v i s i o n o f S t a t i o n a r y S o u r c e En- f o r c e m e n t ) t o t h i s s t u d y . F i n a l l y , t h e a s s i s t a n c e o f t h e a d d i - t i o n a l f o l l o w i n g p e o p l e a t t h e f i e l d s t u d y s i t e is v e r y g r a t e f u l l y acknowledged .

U.S. EPA Beth lehem S t e e l C o r p o r a t i o n

Dave Brooman (Reg ion V I I I ) , C . A . T r a g e s e r

Don C a r e y (D.S.S.E.) R o b e r t Harvey

S t a n l e y Couer (Audio V i s u a l ) Norm Hodgson

P a u l D e P e r c i n (Reg ion V ) Tom K r e i c h e t t

Basim Dihu (Reg ion V ) J o h n Dunn

S t e v e F l o r i n (Reg ion V) C a r o l y n Mance

J o s e p h Kunz (Reg ion 1 1 1 ) Ron S p a l d i n g

Ron M i t c h e l l (Audio V i s u a l ) Dave F i s h e r

Dave S h u l z (Reg ion V) G e r a l d Marchan t

R . Edwin Z y l s t r a (Reg ion V)

T A B L E O F C O N T E N T S

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Page - VOLUME 1

GLOSSARY OF TERMS ......................................... v

LIST OF FIGURES ........................................... Viii

LIST OF TABLES ............................................ ix

LIST OF APPENDICES ............................................ xi

1.0 INTRODUCTION ......................................... 1

2.0 SUMMARY AND CONCLUSIONS .............................. 1 2

2.1 Coke-Side Particulate Emissions ................. 1 2

2.1.1 Overall continuous coke-side particulate

2.1.2 Continuous particulate emissions from the

2.1.3 Peak particulate emissions from the ex-

2.1.4 Fugitive particulate emissions from the

2.1.5 Particulate emissions for pushing opera-

2.1.6 Particulate emissions far non-pushing

emissions ................................ 1 2

exhaust duct ............................. 1 3

haust duct ................................ 13

shed ..................................... 14

tions .................................... 14

operations ............................... 1 4

2.2 Shed Particulate Capture Efficiency ............. 1 5

2.2.1 Evaluation of shed capture efficiency .... 15 2.2.2 Possible causes of leakage ............... 1 5

2.3 Chemical Composition of Particulate Emissions ... 16

2.4 Particle Size Distribution ...................... 16

2.5 Emissions of Other Materials .................... 16

2.6 Dustfall Measurements ........................... 16

2.7 Indices of Visible Emissions .................... 17

2.7.1 Degree of greenness ...................... 17 2.7.2 Opacity .................................... 17

2.7 .3 P e r c e n t o f d o o r s l e a k i n g ................ 18

2.8 P r o c e s s a n d E m i s s i o n s C o r r e l a t i o n s ............. 18

2 . 9 R e p r e s e n t a t i v e n e s s o f P r o c e s s a n d Shed C o n d i t i o n s ..................................... 1 9

3 .0 PROCESS DESCRIPTION AND OPERATIONS ................... 20

3 .1 P r o c e s s D e s c r i p t i o n ............................ 20

3 . 2 R e p r e s e n t a t i v e n e s s o f P r o c e s s a n d Shed Con- d i t i o n s ........................................ 25

3 . 2 . 1 C r i t e r i a f o r c o m p a r i s o n ................. 25 3 . 2 . 2 C o n d i t i o n s d u r i n g s a m p l i n g p e r i o d s ...... 28

3.3 I d e n t i f i c a t i o n of P o s s i b l e N o r m a l i z i n g F a c t o r s . . 32

4 .0 SAMPLING A N D ANALYTICAL METHODS ...................... 33

4 . 1 T e s t P r o t o c o l .................................. 33

4.2 L o c a t i o n o f S a m p l i n g P o i n t s .................... 34

4.3 C o n t i n u o u s P a r t i c u l a t e E m i s s i o n s f rom Shed E x h a u s t Duct ................................... 35

4 .4 D e t e r m i n a t i o n of Peak P a r t i c u l a t e E m i s s i o n P e r i o d 3 9

4 . 5 Peak P a r t i c u l a t e E m i s s i o n s f rom Shed E x h a u s t D u c t 4 3

4.6 P a r t i c l e S i z e D i s t r i b u t i o n . . . . . . ................ 43

4.7 E m i s s i o n s o f O t h e r M a t e r i a l s ................... 44

4.8 D u s t f a l l Measuremen t s .......................... 45

4 . 9 S u b j e c t i v e a n d V i s u a l E m i s s i o n P a r a m e t e r s ...... 46

4 . 9 . 1 Degree of g r e e n n e s s ..................... 46 4.9.2 O p a c i t y o f s h e d e x h a u s t ................. 47 4 . 9 . 3 P e r c e n t of d o o r s l e a k i n g . . . . ............. 4 7 4 .9 .4 V i s u a l e s t i m a t e s o f f u g i t i v e e m i s s i o n s . .. 48

4.10 F u g i t i v e P a r t i c u l a t e E m i s s i o n s From t h e Shed ... 48

4 . 1 1 C a l i b r a t i o n s , Q u a l i t y A s s u r a n c e , a n d S a m p l i n g I n t e g r i t y ...................................... 49

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Page . 5.0 PRESENTATION AND DISCUSSION OF RESULTS ............... 51

5.1

5.2

5.3

5.4

5.5

5.6

.a . 5.7

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5.8

Coke-S ide P a r t i c u l a t e E m i s s i o n s ................. 51

5.1.1 C o n t i n u o u s p a r t i c u l a t e e m i s s i o n s f r o m t h e e x h a u s t d u c t ............................. 51

5.1.2 F u g i t i v e p a r t i c u l a t e e m i s s i o n s ........... 53 5.1.3 O v e r a l l c o n t i n u o u s c o k e - s i d e p a r t i c u l a t e

e m i s s i o n s ................................ 54 5.1.4 Peak p a r t i c u l a t e e m i s s i o n s f r o m t h e s h e d . 56 5.1.5 P a r t i c u l a t e e m i s s i o n s f o r p u s h i n g o p e r a -

t i o n s .................................... 59 5.1.6 P a r t i c u l a t e e m i s s i o n s f o r n o n - p u s h i n g

o p e r a t i o n s ............................... 62

P a r t i c u l a t e C a p t u r e E f f i c i e n c y o f t h e Shed ...... 65

5.2.1 E v a l u a t i o n o f s h e d c a p t u r e e f f i c i e n c y .... 65 5.2.2 P o s s i b l e c a u s e s of l e a k a g e ............... 65 Chemica l C o m p o s i t i o n o f P a r t i c u l a t e E m i s s i o n s ... 69

P a r t i c l e S i z e D i s t r i b u t i o n ...................... 69

E m i s s i o n s o f O t h e r M a t e r i a l s .................... 77

I n d i c e s o f V i s i b l e E m i s s i o n s .................... 80

5.6.1 Degree o f g r e e n n e s s ...................... 80 5.6.2 O p a c i t y .................................. 88

5.6.2.1 E m i s s i o n s f r o m e x h a u s t d u c t ..... 8 8 5.6.2.2 F u g i t i v e e m i s s i o n s .............. 89

5.6.3, P e r c e n t o f d o o r s l e a k i n g ................. 90

E m i s s i o n - R e l a t e d C o r r e l a t i o n s ................... 92

5.7.1 C o r r e l a t i o n s b e t w e e n e m i s s i o n f a c t o r s and

5.7.2 C o r r e l a t i o n s b e t w e e n e m i s s i o n f a c t o r s and

5.7.3 C o r r e l a t i o n s i n v o l v i n g p a r t i c l e s i z e

5.7.4 C o r r e l a t i o n s b e t w e e n i n d i c e s o f v i s i b l e

5.7.5 C o r r e l a t i o n s among v i s i b l e e m i s s i o n s

i n d i c e s o f v i s i b l e e m i s s i o n s ............. 92

p r o c e s s c o n d i t i o n s ....................... 93

d i s t r i b u t i o n s ............................ 94

e m i s s i o n s and p r o c e s s c o n d i t i o n s ......... 94

m e a s u r e m e n t s ............................. 1 0 1

E f f e c t o f t h e Shed Upon D u s t f a l l ................ 103

iv

5.9 Impac t o f t h e Shed Upon A i r b o r n e A g e n t s W i t h i n t h e Shed . ........................................ 115

5.10 P r e c i s i o n of T e s t R e s u l t s ....................... 115

6 . 0 REFERENCES ........................................... 1 1 7

7.0 SOME ANTICIPATED QUESTIONS AND ANSWERS RELATED TO THIS PROJECT .............................................. 118

VOLUME 2

A p p e n d i c e s A-E (See page x i f o r t i t l e s )

VOLUME 3

A p p e n d i c e s F-H (See page x i f o r t i t l e s )

VOLUME 4

A p p e n d i c e s 1-0 (See page x i f o r t i t l e s

VOLUME 5

A p p e n d i c e s P-MM (See p a g e s xi a n d x i i f o r t i t l e s )

VOLUME 6

A p p e n d i c e s NN-WW (See page x i i i f o r t i t l e s )

VOLUME 7

A p p e n d i c e s XX-22 (See p a g e x i i i f o r t i t l e s )

VOLUME 8

Appendix AAA (See page xiii f o r t i t l e s )

VOLUME 9

Appendix BBB (See page x i i i f o r t i t l e s )

VOLUME 10

Appendix C C C (See page x i i i f o r t i t l e s )

VOLUME 11

Appendix DDD (See page x i i i f o r t i t l e s )

VOLUME 1 2

A p p e n d i c e s E E E - G G G (See p a g e x i v f o r t i t l e s )

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V

GLOSSARY OF TERMS

Abnormal operating conditions

Net coking time outside the normal range of net coking time or any coke pushing stoppage greater than 30 minutes duration.

Atypical operating conditions

Extremely infrequent major process changes (or upsets).

Coke-pushing emissions

An intermittent source emission lasting about 15 to 4 5 seconds, occurring on an irregular cycle with an average interval be- tween pushes of 1 3 minutes.

Coke-pushing operations emissions

The aggregate of two source emissions: 1) coke-pushing emis- sions and 2 ) quench car movement emissions which occur under the shed.

Coke side

That side of a coke-oven battery from which the ovens are emptied of coke.

Continuous particulate emissions

The mass particulate emissions measured on the coke side of the coke battery on a continuous basis, spanning periods when pushes occurred as well as intervals between pushes (unless process upsets or downtime exceeded 30 minutes).

Degree of greenness of a coke-oven push

A subjective, visual estimate of the quantity of emissions released during a single coke-oven push by estimation of the plume obscuration immediately above the quench car.

Door 1 ea kage

Any visible emissions observed emanating from coke-side oven doors, push-side oven doors, or push-side chuck doors,

Filterable particulate

Material captured at a specified temperature, pressure, and chemical activity, on or before the front filter in a partic- ulate sampling train.

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10. Fugitive particulate emissions

Particulate emissions which escaped capture by the shed and passed unrestrained into the atmosphere. This does not in- clude emissions resulting from quench car travel outside the shed.

11. Minimum coking time

The elapsed time, in minutes, specified by the operator of the coke production facility as being the minimum net coking time necessary to provide adequate quality coke for produc- tion purposes.

12. Net coking time

The elapsed time, in minutes, between the charging of a coke oven with coal and the pushing of that same oven.

13. Normal operating conditions

Any typical operating conditions not abnormal.

14. Normalization factor

A variable used to relate a mass emission rate to the rate of processing. An example is "tons of dry coal charged."

15. Overall continuous coke-side particulate emissions

The sum of the continuous particulate emissions and the con- tinuous fugitive particulate emissions.

16. Peak particulate emissions

The mass particulate emissions from the exhaust duct measured on the coke side of the coke battery during only the initial 3-minute periods beginning with the commencement of each coke- oven push.

1 7 . Precision of a test result

The statistical confidence interval associated with the mean value of a series of replicate measurements at a decision- risk level of five percent.

18. Push-only particulate emissions

The mass particulate emissions measured on the coke side of the coke battery and resulting only from the pushing opera- tions.

v i i

19. Quench c a r movement e m i s s i o n s

An i n t e r m i t t e n t s o u r c e e m i s s i o n e m a n a t i n g f rom t h e coke i n t h e quench ca r and l a s t i n g a b o u t 15-45 s e c o n d s , f rom t h e e n d o f a coke -oven p u s h u n t i l t h e quench c a r e x i t s f rom t h e s h e d .

T o t a l p a r t i c u l a t e

M a t e r i a l c a p t u r e d a t a s p e c i f i e d t e m p e r a t u r e , p r e s s u r e , and c h e m i c a l a c t i v i t y i n t h e e n t i r e p a r t i c u l a t e s a m p l i n g t r a i n , i . e . , f i l t e r a b l e and c o n d e n s i b l e f r a c t i o n s .

T y p i c a l o p e r a t i n g c o n d i t i o n s

Any p r o c e s s o p e r a t i n g c o n d i t i o n s n o t a t y p i c a l .

I

FIGURE 3.1-1

FIGURE 3.1-2

FIGURE 3.1-3

FIGURE 4.2-1

FIGURE 4.2-2

FIGURE 4.2-3

FIGURE 4.4-1

FIGURE 4.4-2

FIGURE 5.1.5

FIGURE 5.4

FIGURE 5.7.4-1

FIGURE 5.7.4-2

FIGURE 5.7.4-3

FIGURE 5.7.4-4

FIGURE 5.7.5-1

FIGURE 5.7.5-2

FIGURE 5.7.5-3

viii

LIST OF FIGURES

Schematic Diagram of By-product, Metal- lurgical Coke Manufacturing Facility with Dustfall Sites

Schematic Diagram of Coke-Side Shed

Schematic Diagram of Coke-Side Shed End Openings

Schematic Diagram of Sampling Point Loca- tions for "Continuous" Particulate Samples

Schematic Diagram of Sampling Point Loca- tions for "Peak" Particulate Samples

Schematic Diagram of Sampling Point Loca- tions for All Samples Except Particulate

Sequential Filter Obscurity Test on February 24, 1975

Sequential Filter Obscurity Test on March 3, 1975

Schematic Diagram of Sampling Schedule

Particle Size Distributions in Exhaust Duct

Net Coking Time Versus Opacity for Partic- ulate Sampling Days

Degree of Greenness Versus Net Coking Time for Particulate Sampling Days

2 1

23

24

36

37

38

40

41

6 1

74

96

98

Opacity Versus Flue Temperature for Partic- 99 ulate Sampling Days

Degree of Greenness Versus Flue Temperature 100 for Particulate Sampling Days

Opacity Versus Degree of Greenness for Par- 102 ticulate Sampling Days

Composite Graph of Shed Exhaust Duct Opac- 104 ity Versus Time

Shed Exhaust Duct Opacity Versus Time for 105 Various Net Coking Times

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TABLE 1 .0-1

TABLE 1.0-2

TABLE 1 . 0 - 3

TABLE 3 . 2 . 1

TABLE 3 . 2 . 2 - 1

TABLE 3 . 2 . 2 - 2

TABLE 4 . 4

T A B L E 5 . 1 . 1

TABLE 5 . 1 . 2

TABLE 5 .1 .3

TABLE 5 . 1 . 4

TABLE 5 . 1 . 5

TABLE 5 . 1 . 6

TABLE 5 . 3 - 1

TABLE 5.3-2

TABLE 5 .3-3

TABLE 5.4

TABLE 5.5

i x

LIST OF TABLES Page -

G e n e r a l i z e d R o s t e r of E m i s s i o n s I n v e s t i g s t i o n s

3

P u r p o s e ( s ) f o r S a m p l i n g E a c h C o n t a m i n a n t 5

P r o j e c t P a r t i c i p a n t s

P e r t i n e n t P a r a m e t e r s

Compar i son o f Key P r o c e s s P a r a m e t e r s ( B a t t e r y No. 1 )

Compar i son o f Key P r o c e s s P a r a m e t e r s ( B s t t e r y No. 2 )

D e t e r m i n a t i o n o f Peak P a r t i c u l a t e Emia P e r i o d From t h e E x h a u s t Duc t

II.

i

10

27

29

30

n 42

Summary o f C o n t i n u o u s P a r t i c u l a t e E m i s s i o n s 52 From t h e B a t t e r y No. 1 E x h a u s t D u c t

Measured F u g i t i v e P a r t i c u l a t e E m i s s i o n s 5 5 E s c a p i n g From t h e Shed

Summary o f O v e r a l l C o n t i n u o u s P a r t i c u l a t e 57 E m i s s i o n s From t h e Shed

Summary o f P e a k P a r t i c u l a t e E m i s s i o n s From 58 t h e B a t t e r y No. 1 E x h a u s t Duc t

C a l c u l a t i o n o f F t l t e r a b l e P a r t i c u l a t e 6 3 E m i s s i o n F a c t o r f o r P u s h i n g O p e r a t i o n s

C a l c u l a t i o n o f F i l t e r a b l e P a r t i c u l a t e 64 E m i s s i o n F a c t o r f o r Non-Pushing O p e r a t i o n s

Summary of M e t a l s a n d S u l f a t e C o n t e n t o f 70 P a r t i c u l a t e S a m p l e s

Summary of A v e r a g e R a t e s of P a r t i c u l a t e 7 1 E m i s s i o n s From E x h a u s t D u c t

Summary o f W a t e r S o l u b l e pH a n d A c i d i t y / 73 A l k a l i n i t y o f P a r t i c u l a t e S a m p l e s

P a r t i c u l a t e C o n c e n t r a t i o n and A c e t o n e - 76 S o l u b l e C o n t e n t o f P a r t i c l e S i z e S a m p l e s

Summary o f A v e r a g e E m i s s i o n R a t e s o f 7 8 " 0 t h e r " E m i s s i o n s

TABLE 5.6.1-1

TABLE 5.6.1-2

TABLE 5.6.1-3

TABLE 5.6.1-4

TABLE 5.6.1-5

TABLE 5.6.1-6

TABLE 5.6.1-7

TABLE 5.6.3

TABLE 5.8-1

TABLE 5.8-2

TABLE 5.8-3

TABLE 5.8-4

P.ga

C h a r a c t e r i s t i c . of I n d i v i d u a l P u i h e s 81 D u r i n g P a r t i c u l a t e S a m p l i n g - C o n t i n u o u s P a r t i c u l a t e T e s t No. 1

C h a r a c t e r i s t i c s of I n d i v i d u a l P u s h e s D u r i n g 82 P a r t i c u l a t e S a m p l i n g - Peak P a r t i c u l a t e T e s t No. 1

c h a r a c t e r i s t i c s o f I n d i v i d u a l P u s h e s D u r i n g 83 P a r t i c u l a t e S a m p l i n g - C o n t i n u o u s P a r t i c u l a t e T e s t No. 2

C h a r a c t e r i s t i c s o f I n d i v i d u a l P u s h e s D u r i n g 8 4 P a r t i c u l a t e S a m p l i n g - Peak P a r t i c u l a t e T e a t No. 2

C h a r a c t e r i s t i c s o f I n d i v i d u a l P u s h e s D u r i n g 85 B a i - t i c u l a t e S a m p l i n g - C o n t i n u o u s P a r t i c u l a t e T e s t No. 3

C h a r a c t e r i s t i c s o f I n d i v i d u a l P u s h e s D u r i n g P a r t i c u l a t e S a m p l i n g - Peak P a r t i c u l a t e T e s t No. 3

P u s h C h a r a c t e r i s t i c s D u r i n g P a r t i c l e S i z e S a m p l i n g

Door Leakage o n P a r t i c u l a t e S a m p l i n g Days

Summary o f D u s t f a l l Measuremen t s s t B a t t e r i e s 1 and 2

Summary of A c e t o n e - S o l u b l e and C y c l o h e x a n e - S o l u b l e C o n t e n t o f S e l e c t e d D u s t f a l l Samples

Summary o f pH o f S e l e c t e d D u s t f a l l Samplea

F o r m a t Used f o r A n a l y s e s o f D u s t f a l l Da ta (gm/m2/wk)

86

87

91

107

1 0 9

110

113

.

. " I " I

. r

xi

LIST OF APPENDICES

VOLUME 2

A BSC Coke-Oven Pushing Schedule

B BSC Pusher Reports

C BSC Coke-Oven Daily Data (Coal and Coke Analyses) L'?,

2 D BSC Coal Charge Rate and Coal Analyses

E BSC Coke-Oven Fuel-Gas Analyses L

VOLUME 3

F BSC Coal Weights for Each Charge

G BSC Cross-Wall Temperature Graphs

H BSC Full-Span Pyrometer Data

VOLUME 4

I BSC Oven Pressure and Temperature Data

J BSC Collector-Main Pressure and Underfire Gas Flow Data

K BSC Flue Inspection Reports

L BSC Coke Inspection Reports

i M BSC Fan Curves and Fan Power Data

N BSC Visible Emissions Ratings

0 BSC Meteorological Data

VOLUME 5

P EPA Method 1 - Sample and Velocity Traverses for Stationary Sources

Q EPA Method 2 - Determination of Stack Gas Velocity and Volu- metric Plowrate (Type S Pitot Tube)

R EPA Method 5 -Determination of Particulate Emissions from Stationary Sources

S Determination of Particulate Emissions from Coke-Oven Pushing

T

U.

V

W

X

Y

2

AA

BB

cc

DD

EE

FF

GG

HH

I1

33

KK

LL

MM

xii

Determination of Peak Particulate Emission Period from an Exhaust Duct

Determination of Particle Sizing During Coke-Oven Pushing

EPA Method 8 -Determination of Sulfuric Acid Mist and Sulfur Dioxide Emissions from Stationary Sources

EPA Method 1 1 - Determination of Hydrogen Sulfide Emissions from Stationary Sources

Determination of Ammonia Emissions from Coke-Oven Pushing

Determination of Various Emissions Absorbed in Sodium Hydroxide from Coke-Oven Pushing

Determination of Various Emissions Adsorbed on Activated Carbon from Coke-Oven Pushing

Determination of Various Emissions Captured in a Glass Gas Burette During Coke-Oven Pushing

Determination of Various Emissions Absorbed in Cyclohexane from Coke-Oven Pushing

Determination of Dustfall (Particulate Fallout) Near Coke Ovens

Determination of Degree of Greenness o f a Coke-Oven Push

EPA Method 9 -Visual Determination of the Opacity of Emis- sions from Stationary Sources

Determinatton of the Percent of Doors Leaking

Determination of Estimated Fugitive Emissions from Coke-Oven Pushing

Assessment of the Fugitive Particulate Emissions Escaping from a Coke-Side Shed

Calibration Procedures

Calibration Data

Void Samples

Field Sampling Data

Analytical Data

f I '

x i i i

VOLUME 6

N N

00

PP

QQ

R R

ss

T T

uu vv

ww

C h a i n - o f - C u s t o d y P r o c e d u r e s f o r A i r P o l l u t i o n E m i s s i o n S amp 1 i n g

Example C a l c u l a t i o n s

C o r r e s p o n d e n c e f r o m B e t h l e h e m S t e e l C o r p o r a t i o n

R e s u l t s o f P r e v i o u s BSC S a m p l i n g

R e s u l t s o f C o n t i n u o u s P a r t i c u l a t e S a m p l i n g

R e s u l t s o f P e a k P a r t i c u l a t e S a m p l i n g

R e s u l t s o f P a r t i c l e S i z e S a m p l i n g

R e s u l t s o f S a m p l i n g f o r "Othe r " E m i s s i o n s

EPA D e g r e e - o f - G r e e n n e s s D a t a

EPA E v a l u a t i o n o f V i s i b l e E m i s s i o n s E x h a u s t e d f r o m t h e Shed

VOLUME 7

XX EPA E v a l u a t i o n o f V i s i b l e E m i s s i o n s f o r Shed End Leakage

\ YY EPA Door Leak O b s e r v a t i o n s

ZZ P u s h E m i s s i o n C h a r t s - B a t t e r y No, 1

I VOLUME 8

AAA Record f o r Coke-S ide a n d P u s h - S i d e Doors - B a t t e r y No. 1

VOLUME 9

BBB Shed C a p t u r e P e r f o r m a n c e and M i s c e l l a n e o u s Da ta - B a t t e r y No. 1

VOLUME 10

CCC P u s h E m i s s i o n C h a r t s - B a t t e r y No. 2

VOLUME 11

DDD Record f o r Coke-Side a n d P u s h - S i d e D o o r s - B a t t e r y No. 2

VOLUME 12

EEE Pre l iminary Tabula t ions Forwarded to EPA

F F P A d d i t i o n a l Attempted C o r r e l a t i o n s

G G G R e s u l t s o f D u s t f a l l Sampling

SOURCE TESTING OF A STATIONARY COKE-SIDE ENCLOSURE

(Volume 1 o f 12)

B u r n s H a r b o r P l a n t B e t h l e h e m S t e e l C o r p o r a t i o n

Chea t e r t o n , I n d i a n a

C o n t r a c t No. 68-02-1400 T a s k No. 10

P r e p a r e d f o r :

D i v i s i o n o f S t a t i o n a r y S o u r c e E n f o r c e m e n t T e c h n i c a l S u p p o r t B r a n c h

U.S. E n v i r o n m e n t a l P r o t e c t i o n Agency W a s h i n g t o n , D . C . 20460

P r o j e c t O f f i c e r :

L o u i s R. P a l e y , P.E.

May 20, 1 9 7 7

P r e p a r e d by:

C l a y t o n E n v i r o n m e n t a l C o n s u l t a n t s , I n c . 25711 S o u t h f i e l d Road

S o u t h f i e l d , M i c h i g a n 48075

L.

T h i s r e p o r t was f u r n i s h e d t o t h e U.S. E n v i r o n m e n t a l P r o t e c t i o n Agency by C l a y t o n E n v i r o n m e n t a l C o n s u l t a n t s , I n c . , S o u t h f i e l d , M i c h i g a n , i n f u l f i l l m e n t o f C o n t r a c t No. 68-02-1408, Task O r d e r N O . 10. The c o n t e n t s o f t h i s r e p o r t a r e r e p r o d u c e d h e r e i n a s r e c e i v e d f rom t h e c o n t r a c t o r . The o p i n i o n s , f i n d i n g s , and con- c l u s i o n s e x p r e s s e d a r e t h o s e of t h e a u t h o r s and n o t n e c e s s a r i l y t h o s e o f t h e U.S. E n v i r o n m e n t a l P r o t e c t i o n Agency.

The E n f o r c e m e n t T e c h n i c a l G u i d e l i n e s e r i e s o f r e p o r t s is i s s u e d by t h e O f f i c e o f E n f o r c e m e n t , E n v i r o n m e n t a l P r o t e c t i o n Agency , t o a s s i s t t h e R e g i o n a l O f f i c e s i n a c t i v i t i e s r e l a t e d t o e n f o r c e m e n t o f i m p l e m e n t a t i o n p l a n s , new s o u r c e e m i s s i o n s t a n d a r d s , and h a z - a r d o u s e m i s s i o n s t a n d a r d s t o be d e v e l o p e d u n d e r t h e C l e a n A i r A c t . C o p i e s o f E n f o r c e m e n t T e c h n i c a l G u i d e l i n e r e p o r t s a r e a v a i l a b l e - a s s u p p l i e s p e r m i t - f rom A i r P o l l u t i o n T e c h n i c a l I n f o r m a t i o n C e n t e r , E n v i r o n m e n t a l P r o t e c t i o n Agency , R e s e a r c h T r i a n g l e P a r k , N o r t h C a r o l i n a , 27711, o r may be o b t a i n e d , f o r a n o m i n a l c o s t , f rom t h e N a t i o n a l T e c h n i c a l I n f o r m a t i o n S e r v i c e , 5285 P o r t R o y a l Road , S p r i n g f i e l d , V i r g i n i a , 22161.

.

.

.

1 . O I N T R O D U C T I O N

The U . S . E n v i r o n m e n t a l P r o t e c t i o n Agency commiss ioned C l a y t o n

E n v i r o n m e n t a l C o n s u l t a n t s , I n c . ( T a s k 1 0 , C o n t r a c t No. 6 8 - 0 2 - 1 4 0 8 )

t o q u a n t i f y t h e n a t u r e a n d e x t e n t o f p a r t i c u l a t e and g a s e o u s emis-

s i o n s t y p i c a l l y e m a n a t i n g f rom t h e c o k e s i d e of Coke B a t t e r y No. 1

a t t h e Burns H a r b o r p l a n t o f B e t h l e h e m S t e e l C o r p o r a t i o n i n

C h e s t e r t o n , I n d i a n a . T h i s i n f o r m a t i o n was o b t a i n e d t o h e l p p r o v i d e

a b a s i s f o r :

1. Development o f EPA p o l i c y on c o k e - s i d e coke b a t t e r y emis-

s i o n s a n d t h e i r c o n t r o l ;

2 . A s s e s s m e n t o f t h e a d e q u a c y of S t a t e I m p l e m e n t a t i o n P l a n s

t o a c h i e v e P r i m a r y A i r Q u a l i t y S t a n d a r d s i n a r e a s c o n t i g -

uous t o c o k e p l a n t s ; a n d

3 . A s s e s s m e n t of t h e a d e q u a c y o f c o n t r o l d e v i c e s b e i n g p r o -

posed f o r a b a t e m e n t of s u c h e m i s s i o n s .

Measurement of t h e n o r m a l l y f u g i t i v e c o k e - s i d e e m i s s i o n s w a s

f a c i l i t a t e d a t Burns H a r b o r by t h e e x i s t e n c e of a p e r m a n e n t , 4 0 0 -

f o o t l o n g , c a n o p y - t y p e h o o d , commonly t e r m e d " c o k e - s i d e s h e d ,'I

t h a t s e m i - e n c l o s e d t h e coke s i d e of B a t t e r y No. 1.

The f o l l o w i n g two m a j o r componen t s c o m p r i s e d t h e c o k e - s i d e

e m i s s i o n s r e l e a s e d i n t o t h e s h e d :

1. 'Coke-push ing o p e r a t i o n e m i s s i o n s r e s u l t i n g f r o m :

a . Coke p u s h i n g - a n i n t e r m i t t e n t s o u r c e e m i s s i o n l a s t i n g

a b o u t 1 5 t o 45 s e c o n d s a n d o c c u r r i n g on a n i r r e g u l a r

b a s i s w i t h a n a v e r a g e i n t e r v a l b e t w e e n p u s h e s o f 13

m i n u t e s ;

b. Quench car movement- a n i n t e r m i t t e n t s o u r c e e m i s s i o n

e m a n a t i n g f rom t h e coke i n t h e quench c a r and l a s t i n g

,

- 2 -

a b o u t 15 t o 45 s e c o n d s , f rom t h e end o f

a coke -oven p u s h u n t i l t h e quench car e x i t s

f rom t h e s h e d ; a n d

2 . L e a k i n g c o k e - s i d e d o o r s e m i s s i o n s ; i n t h e a g g r e g a t e ,

t h e 8 2 c o k e - s i d e d o o r s o f B a t t e r y No. 1 r e l e a s e d emis-

s i o n s a t a f a i r l y c b n s t a n t r a t e .

T h e s e two e m i s s i o n componen t s - e s p e c i a l l y t h e p u s h i n g o p e r a t i o n -

c a u s e d t h e e m i s s i o n s conveyed t h r o u g h t h e s h e d e x h a u s t d u c t t o v a r y

w i d e l y w i t h r e s p e c t t o p a r t i c u l a t e c o n c e n t r a t i o n , o p a c i t y , c h e m i c a l

c o m p o s i t i o n , t e m p e r a t u r e , and p a r t i c l e s i z e a s a f u n c t i o n o f - t i m e .

S i n c e the s h e d w a s i n s t a l l e d t o c a p t u r e and t r a n s p o r t a l l o f

t h e c o k e - s i d e e m i s s i o n s t o a r e t r o f i t t e d c o n t r o l d e v i c e ( n o t i n -

s t a l l e d a t t h e t i m e o f t h i s s t u d y ) , t h e o r i g i n a l t e s t i n g p r o t o c o l

s p e c i f i e d e m i s s i o n t e s t s o n l y i n t h e ( i n d u c e d d r a f t ) d u c t t h a t

e x h a u s t e d t h e s h e d . D u r i n g t h e t e s t s , h o w e v e r , v i s i b l y - s i g n i f i c a n t

q u a n t i t i e s o f p a r t i c u l a t e e m i s s i o n s were o b s e r v e d l e a k i n g f rom t h e

s h e d , i n d i c a t i n g t h a t t h e s h e d ' s c a p t u r e a n d t r a n s p o r t e f f i c i e n c y

was l e s s t h a n 1 0 0 p e r c e n t . T h e r e f o r e , t h e s c o p e o f t h e p r o j e c t

was expanded t o p r o v i d e a n e s t i m a t e of t h e m a g n i t u d e o f t h e s e l e a k 8

F i n a l l y , t o be f u l l y r e s p o n s i v e t o t h e n e e d s a n d o b j e c t i v e s ( 1 , 2 )

o f t h i s t e s t p r o g r a m , a l a r g e number o f a d d i t i o n a l , e x p e c t e d

a i r c o n t a m i n a n t s w e r e measu red d u r i n g t h i s s t u d y a s shown i n

T a b l e 1 .0-1 . The r a t i o n a l e and p u r p o s e s f o r s a m p l i n g e a c h o f t h e s e

m a t e r i a l s a r e g i v e n i n T a b l e 1 . 0 - 2 .

The f i e l d s a m p l i n g p o r t i o n of t h e s t u d y was p e r f o r m e d on March

3 - 7 , 1 9 7 5 , a f t e r some i n i t i a l r a n g e - f i n d i n g d e t e r m i n a t i o n s were

made on F e b r u a r y 2 4 , 1975. The r a n g e - f i n d i n g d e t e r m i n a t i o n s

i n c l u d e d e x h a u s t g a s f l o w r a t e , m o i s t u r e c o n t e n t , g a s c o m p o s i t i o n

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- 9 -

(during pushing only and also as a continuous or integrated

measurement), temperature, and filter obscurity. A list of

project participants.is given in Table 1.0-3.

Some possible questions and answers that may arise while

reading this report are listed in Section 7.0.

- 10 -

TABLE 1 .0 -3

PROJECT PARTICIPANTS . Burns H a r b o r P l a n t

Be th lehem S t e e l C o r p o r a t i o n C h e s t e r t o n , I n d i a n a

March 3 - 7 , 1975

U.S. E n v i r o n m e n t a l P r o t e c t i o n Agency D i v i s i o n o f S t a t i o n a r y S o u r c e E n f o r c e m e n t

L o u i s R. P a l e y , P.E., P r o j e c t O f f i c e r Mark A n t e l l B e r n a r d Bloom Don C a r e y

U. S. E n v i r o n m e n t a l P r o t e c t i o n Agency, R e g i o n I11

J o s e p h W. Kunz

U. S. E n v i r o n m e n t a l P r o t e c t i o n Agency, R e g i o n V

R. Edwin Z y l s t r a Dave S h u l z P a u l R. D e P e r c i n S teve F l o r i n B a s i m Dihu

U.S. E n v i r o n m e n t a l P r o t e c t i o n Agency N a t i o n a l E n f o r c e m e n t I n v e s t i g a t i o n C e n t e r , R e g i o n V I 1 1

Dave Brooman

U.S. E n v i r o n m e n t a l P r o t e c t i o n Agency Audio V i s u a l Branch

Ron M i t c h e l l S t a n l e y Couer

B e t h l e h e m S t e e l C o r p o r a t i o n

C.A. T r a g e s e r R o b e r t M. Harvey Norm D. Hodgson Tom K r e i c h e t t J o h n T. Dunn C a r o l y n Mance Ron K. S p a l d i n g Dave F i s h e r G e r a l d Marchan t

, *"

- 11 -

TABLE 1 .0-3 ( c o n t i n u e d )

PROJECT P A R T I C I P A N T S

JI.

B u r n s H a r b o r P l a n t Be th lehem S t e e l C o r p o r a t i o n

Che s t e r t o n , March 3 - 7 , 1 9 7 5

I n d i a n a

C l a y t o n E n v i r o n m e n t a l C o n s u l t a n t s , I n c .

?+> F i e l d Team

L. R i c h a r d J. P o w a l s , P.E. P r o j e c t L e a d e r V i c t o r W. Hanson S e n i o r E n v i r o n m e n t a l C o n t r o l S p e c i a l i s t F r e d I. Cooper Group L e a d e r , S o u r c e S a m p l i n g S t u d i e s R i c h a r d G. Kel le r E n v i r o n m e n t a l C o n t r o l S p e c i a l i s t R i c h a r d C. Marcus E n v i r o n m e n t a l C o n t r o l S p e c i a l i s t R i c h a r d J. G r i f f i n E n v i r o n m e n t a l C o n t r o l S p e c i a l i s t G e r a l d E. Hawkins E n v i r o n m e n t a 1 Co n t r o 1 S p e c i a l i s t Kent D. Shoemaker C h e m i s t

Data A n a l y s t s

J a n e t L. Vecch io Rebecca B. Cooper

L a b o r a t o r y A n a l y s t s

A i l e e n G. Hayes David J. Holmberg John Knowles M i c h a e l D. K e l l y Nathan C. R i d d l e Kent D. Shoemaker James M. McCla in

Group L e a d e r , D a t a P r o c e s s i n g E n v i r o n m e n t a l C o n t r o l S p e c i a l i s t

A s s i s t a n t D i r e c t o r , L a b o r a t o r y S e r v i c e s Labor a t o r y S h i f t S u p e r v i s o r Chemis t Chemis t C h e m i s t Chemis t C h e m i s t

Managing C o n s u l t a n t

J o h n E. M u t c h l e r , P.E. V i c e - p r e s i d e n t , E n g i n e e r i n g Se rv ices

C l a y t o n E n v i r o n m e n t a l C o n s u l t a n t s , I n c .

\

- 1 2 - 2 . 0 SUMMARY AND CONCLUSIONS

2 . 1 Coke-Side P a r t i c u l a t e E m i s s i o n s

Two t y p e s of p a r t i c u l a t e e m i s s i o n s were o b s e r v e d t o emana te

f rom t h e coke s i d e o f t h e s h e d a t B a t t e r y Not 1 a t t h e Burns

Harbor p l a n t o f B e t h l e h e m S t e e l C o r p o r a t i o n . T h e s e e m i s s i o n s

c o m p r i s e d p a r t i c u l a t e m a t t e r d i s c h a r g e d t h r o u g h t h e s h e d e x h a u s t

d u c t a n d f u g i t i v e p a r t i c u l a t e m a t t e r wh ich e s c a p e d t h e s h e d . The

c o m b i n a t i o n o f t h e s e two e m i s s i o n s is r e f e r r e d t o be low a s " O v e r a l l

C o n t i n u o u s Coke-Side P a r t i c u l a t e E m i s s i o n s . "

2 . 1 . 1 O v e r a l l C o n t i n u o u s Coke-S ide P a r t i c u l a t e E m i s s i o n s

The o v e r 4 1 1 f i l t e r a b l e c o k e - s i d e p a r t i c u l a t e e m i s s i o n s

r a n g e d f rom 0.89 t o 0 . 9 3 , and a v e r a g e d 0 .91 pound p e r t o n o f

d r y c o a l f e d t o t h e o v e n s

e m i s s i o n m e a s u r e m e n t s i n h e r e n t l y i n c l u d e c o n t r i b u t i o n s f rom

t h e f o l l o w i n g s o u r c e s : c o k e - p u s h i n g o p e r a t i o n s ( c o k e push -

i n g and quench c a r movement) , d o o r l e a k s , a n d r e s i d u a l p a r -

t i c u l a t e c o n c e n t r a t i o n s w i t h i n t h e shed volume f rom p r e v i o u s

p u s h e s , a 8 w e l l a s e m i s s i o n s wh ich e s c a p e d t h e s h e d . The

h o u r l y e m i s s i o n r a t e c o r r e s p o n d i n g t o t h e s e e m i s s i o n s r a n g e d

from 143 t o 1 5 1 , and a v e r a g e d 146 pounds p e r h o u r (+ - 10

(+ - 0.06 pound p e r t o n ) . " These

pounds p e r h o u r ) .

B

* The n o t a t i o n 'I+ 0.06 pound p e r t o n " is a n e s t i m a t e o f t h e s t a t i s t T c a 1 p r e c i s i o n o f t h e a v e r a g e v a l u e b a s e d upon a 9 5 - p e r c e n t l e v e l o f c o n f i d e n c e . A l - t h o u g h t h e p r e c i s i o n is + 0 .06 , t h e c o n f i d e n c e i n t e r v a l f o r a c o n c e n t r a T i o n , e m i s s i o n r a t e , o r e m i s s i o n f a c t o r is a l w a y s bounded by a minimum v a l u e o f z e r o . ( S e e S e c t i o n 5 . 1 0 . )

- 13 -

2.1.2 C o n t i n u o u s P a r t i c u l a t e E m i s s i o n s f rom t h e E x h a u s t Duc t - F i l t e r a b l e p a r t i c u l a t e e m i s s i o n m e a s u r e m e n t s made

i n t h e e x h a u s t d u c t e v a c u a t i n g t h e s h e d on a c o n t i n u o u s

b a s i s i n d i c a t e d a n a v e r a g e e m i s s i o n f a c t o r o f 0.78 pound

p e r t o n of d r y c o a l f e d t o t h e o v e n s (+ 0 . 0 4 pound p e r t o n ) .

The c o r r e s p o n d i n g a v e r a g e h o u r l y e m i s s i o n r a t e f o r c o n t i n u -

ous p a r t i c u l a t e e m i s s i o n s w a s 1 2 4 pounds p e r h o u r (+ 1 0

pounds p e r h o u r ) . These e m i s s i o n m e a s u r e m e n t s i n h e r e n t l y

i n c l u d e c o k e - p u s h i n g o p e r a t i o n s e m i s s i o n s , d o o r l e a k s , . a n d

r e s i d u a l e m i s s i o n s from p r e v i o u s p u s h e s , b u t e x c l u d e

f u g i t i v e e m i s s i o n s .

-

-

2 . 1 . 3 Peak P a r t i c u l a t e E m i s s i o n s f rom t h e E x h a u s t Duct

P a r t i c u l a t e e m i s s i o n m e a s u r e m e n t s made d u r i n g t h e

i n i t i a l 3 - m i n u t e p e r i o d when p u s h i n g e m i s s i o n s w e r e b e i n g

e v a c u a t e d f r o m t h e shed ( h e a v i e s t v i s i b l e e m i s s i o n p e r i o d )

i n d i c a t e d a n a v e r a g e e m i s s i o n f a c t o r of 0.64 pound o f

f i l t e r a b l e p a r t i c u l a t e p e r t o n o f d r y c o a l c h a r g e d t o t h e

o v e n s (+ 0.34 pound p e r t o n ) . The c o r r e s p o n d i n g e m i s s i o n

r a t e f o r t h i s p e r i o d a v e r a g e d 93.2 pounds o f f i l t e r a b l e

p a r t i c u l a t e p e r h o u r (+ 47.9 pounds p e r h o u r ) . I t

s h o u l d be n o t e d t h a t b e c a u s e of t h e f r e q u e n c y a n d o v e r a l l

d u r a t i o n o f s a m p l i n g , t h e e m i s s i o n r a t e s f o r t h e s e peak

e m i s s i o n s h a v e b e e n a d j u s t e d t o r e f l e c t t y p i c a l o p e r a t i o n s ;

i . e . , 4.5 p u s h e s p e r h o u r . I n a d d i t i o n , t h e s e v a l u e s i n -

h e r e n t l y i n c l u d e d o o r l e a k s and r e s i d u a l e m i s s i o n s f rom p r e -

v i o u s p u s h e s , b u t e x c l u d e f u g i t i v e e m i s s i o n s .

. -

-

,- .

- 14 - I

2.1.4 F u g i t i v e P a r t i c u l a t e E m i s s i o n s f rom t h e Shed

The f u g i t i v e p a r t i c u l a t e e m i s s i o n s f rom t h e s h e d

o c c u r r e d a t f o u r p o s i t i o n s : The n o r t h a n d s o u t h e n d s of

t h e s h e d , t h e A s k a n i a v a l v e s , a n d t h e b o u n d a r y b e t w e e n t h e

shed and t h e coke b a t t e r y . On a c o n t i n u o u s b a s i s , t h e s e

( f i l t e r a b l e ) f u g i t i v e e m i s s i o n s were e s t i m a t e d t o a v e r a g e

0.14 pound p e r t o n o f d r y c o a l f e d t o t h e o v e n s , o r 21.9

pounds o f f u g i t i v e p a r t i c u l a t e p e r h o u r . R e l a t e d t o t h e

c o n t i n u o u s f i l t e r a b l e p a r t i c u l a t e e m i s s i o n s , t h e y a v e r a g e d

15 p e r c e n t o f t h e o v e r a l l e m i s s i o n s .

I

.

2.1.5 P a r t i c u l a t e E m i s s i o n s f o r P u s h i n g O p e r a t i o n s

U s i n g t h e p a r t i c u l a t e e m i s s i o n s d a t a p r e s e n t e d

p r e v i o u s l y a n d a s t r a i g h t f o r w a r d c a l c u l a t i o n a l p r o c e d u r e ,

i t was p o s s i b l e t o o b t a i n a r o u g h e s t i m a t e of t h e p a r t i c u l a t e

e m i s s i o n 8 a t t r i b u t a b l e t o p u s h i n g o p e r a t i o n s a l o n e a t t h e

Burns H a r b o r p l a n t . T h e s e e m i s s i o n s were e s t i m a t e d t o

a v e r a g e 0.69 pound o f f i l t e r a b l e p a r t i c u l a t e p e r t o n o f

d r y c o a l f e d t o t h e o v e n s (+ 0.51 pound p e r t o n ) . T h i s - e m i s s i o n f a c t o r h a s b e e n a d j u s t e d t o i n c l u d e f u g i t i v e , 4

e m i s s i o n s from t h e s h e d .

2.1.6 P a r t i c u l a t e E m i s s i o n s f o r Non-Pushing O p e r a t i o n s

The o v e r a l l c o k e - s i d e e m i s s i o n s f o r n o n - p u s h i n g

o p e r a t i o n s were r o u g h l y e s t i m a t e d t o a v e r a g e 0.22 pound o f

f i l t e r a b l e p a r t i c u l a t e p e r t o n o f d r y c o a l f e d t o t h e o v e n s

(+ 0.46 7 p,ound p e r t o n ) . T h i s f a c t o r h a s b e e n a d i u s t e d t o -- i n c l u d e f u g i t i v e e m i s s i o n s

- 15 -

U s i n g t h e s e d a t a , p u s h i n g o p e r a t i o n s were f o u n d ,

on an average b a s i s , t o a c c o u n t f o r 76 p e r c e n t of t h e o v e r -

a l l c o k e - s i d e p a r t i c u l a t e e m i s s i o n s , w h i l e 2 4 p e r c e n t were

a t t r i b u t a b l e t o n o n - p u s h i n g o p e r a t i o n s .

. . . . 2 . 2 Shed P a r t i c u l a t e C a p t u r e E f f ' i c i e n c y

Because s i g n i f i c a n t v i s i b l e f u g i t i v e e m i s s i o n s were ob-

s e r v e d e s c a p i n g f rom t h e s h e d d u r i n g t h e s t u d y , and i n o r d e r

f o r EPA t o e v a l u a t e t h e c o s t - e f f e c t i v e n e s s o f t h e s h e d c o n c e p t ,

i t was n e c e s s a r y t o e v a l u a t e t h e p a r t i c u l a t e c a p t u r e e f f i c i e n c y

o f t h e s h e d .

2.2.1 E v a l u a t i o n o f S h e d C a p t u r e E f f i c i e n c y

The e f f i c i e n c y of t h e s h e d i n c a p t u r i n g a n d e x h a u s t - '

i n g c o k e - s i d e e m i s s i o n s f r o m p u s h i n g ( b a s e d upon p a r t i c u l a t e

e m i s s i o n m e a s u r e m e n t s ) w a s found t o be a p p r o x i m a t e l y 85

p e r c e n t . T h u s , on a " c o g 1 5 - p e r c e n t o f t h e p a r t i c u l a t e e m i s s i o n s e s c a p e d f rom t h e s h e d .

2.2.2 P o s s i b l e C a u s e s o f Leakage

S e v e r a l p o t e n t i a l c a u s e s f o r t h e e x i s t e n c e o f f u g i -

t i v e p a r t i c u l a t e e m i s s i o n s h a v e b e e n s u g g e s t e d . These

i n c l u d e t h e f o l l o w i n g :

1. The o v e r a l l m a g n i t u d e o f t h e s h e d ' s h o l d i n g

volume a p p e a r e d t o be t o o s m a l l r e l a t i v e t o t h e

m a g n i t u d e of t h e e m i s s i o n s , and t h e e f f e c t i v e

e x h a u s t r a t e o f t h e s h e d may h a v e been t o o low;

2. I t i s p o s s i b l e t h a t " s h o r t c i r c u i t i n g " o f t h e

o u t s i d e a i r t o t h e e x h a u s t d u c t o c c u r r e d ; and

3. The s h a p e , s i z e , and l o c a t i o n o f t h e h o l d i n g

- 1 6 - chamber a n d / o r t h e e x h a u s t d u c t , as w e l l a s

t h e s h e d w a l l a n d e n d o p e n i n g s , may h a v e

a f f e c t e d t h e c a p t u r e e f f i c i e n c y o f t h e s h e d .

2 . 3 Chemica l C o m p o s i t i o n o f P a r t i c u l a t e E m i s s i o n s

The p a r t i c u l a t e m a t t e r s a m p l e s t a k e n d u r i n g t h i s s t u d y were

s u b j e c t e d t o 1 9 s e p a r a t e a n a l y s e s t o d e t e r m i n e p a r t i c u l a t e com-

p o s i t i o n . The r e s u l t s i n d i c a t e d t h a t t h e p a r t i c u l a t e m a t t e r was

p r e d o m i n a n t l y c a r b o n a c e o u s w i t h u n d e t e c t a b l e o r t r a c e amoun t s of

n e a r l y a l l o t h e r c o n s t i t u e n t s f o r w h i c h a n a l y s e s were p e r f o r m e d .

2 .4 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 s i z e d i s t r i b u t i o n o f p a r t i c u l a t e m a t t e r v a r i e d g r e a t l y

a s a f u n c t i o n o f s a m p l i n g p o s i t i o n i n t h e e x h a u s t d u c t , p r o b a b l y

due t o t h e numerous c h a n g e s i n d i r e c t i o n of t h e e x h a u s t g a s f l o w

w i t h i n t h e d u c t . On a n a v e r a g e b a s i s , h o w e v e r , a p p r o x i m a t e l y 3 2

p e r c e n t of t h e p a r t i c u l a t e w a s s m a l l e r t h a n s e v e n m i c r o n s and

a p p r o x i m a t e l y s e v e n p e r c e n t was s m a l l e r t h a n one m i c r o n .

2 . 5 E m i s s i o n s of O t h e r M a t e r i a l s

I n a d d i t i o n t o p a r t i c u l a t e , s a m p l i n g was c o n d u c t e d t o d e t e r -

mine t h e c o n c e n t r a t i o n of 29 o t h e r p o t e n t i a l a i r c o n t a m i n a n t s f rom

coke p u s h i n g . C y c l o h e x a n e s o l u b l e s a n d i n s o l u b l e s , e t h y l e n e and

homologues , and t o t a l l i g h t h y d r o c a r b o n s were f o u n d t o be

d i s c h a r g e d a t e m i s s i o n r a t e s e x c e e d i n g 100 pounds p e r h o u r . A l l

o t h e r m e a s u r e d c o n t a m i n a n t s w e r e d e t e c t e d a t l e v e l s t h a t a v e r a g e d

l e s s t h a n 16 pounds p e r h o u r .

2 . 6 D u s t f a l l Measu remen t s

D u s t f a l l m e a s u r e m e n t s were t a k e n w i t h i n t h e s h e d on B a t t e r y

NO. 1 a n d a t s imi l a r l o c a t i o n s on t h e a d j o i n i n g unshedded b u t

- 17 -

g e n e r a l l y - c o m p a r a b l e b a t t e r y . The p u r p o s e of t h e s e m e a s u r e m e n t s

was t o a s s e s s t h e s h e d ' s e f f e c t on d u s t f a l l r a t e a t employee

work s t a t i o n s .

i F o r t h r e e o f t h e f o u r l o c a t i o n s c o n s i d e r e d , d u s t f a l l

( s e t t l e a b l e p a r t i c u l a t e ) r a t e s b e n e a t h t h e s h e d were a t a t i s t i -

c a l l y g r e a t e r t h a n t h o s e a t c o r r e s p o n d i n g l o c a t i o n s i n t h e

unshedded No. 2 B a t t e r y . The d u s t f a l l a t t he bench l o c a t i o n ,

t h e p r i m a r y work s t a t i o n , d i d n o t d i f f e r be tween t h e two b a t t e r i e s .

A s e x p e c t e d , g r e a t e r d u s t f a l l r a t e s were e x p e r i e n c e d a t t h e No. 1

B a t t e r y n e a r t h e shed w a l l t h a n a t l o c a t i o n s n e a r e r t h e b e n c h .

T h u s , t h e s h e d ' s d e s i g n e f f e c t i v e l y c a u s e s t h e i n c r e a s e d q u a n t i t y

o f d u s t f a l l t o d r o p away f rom t h e work s t a t i o n s t o a l o c a t i o n

n e a r t h e w a l l of t h e shed .

2

2.7 I n d i c e s o f V i s i b l e E m i s s i o n s

2.7.1 Degree o f G r e e n n e s s

The a v e r a g e v a l u e f o r t h e d e g r e e of g r e e n n e s s of

t h e pushed coke ( p r o d u c t o f t h e sum o f t h e g r e e n n e s s r a t i n g s

and t h e d u r a t i o n o f t h e p u s h ) r a n g e d from 222 t o 285 f o r t h e

t h r e e p a r t i c u l a t e s a m p l i n g p e r i o d s . The t h i r d p a r t i c u l a t e

s a m p l i n g p e r i o d was f o u n d t o c o n t a i n p u s h e s o f h i g h e r

g r e e n n e s s r a t i n g s t h a n t h e o t h e r two s a m p l i n g p e r i o d s .

2.7.2 O p a c i t y

O p a c i t y d a t a were a c q u i r e d f o r t h e two s t a c k s d i s -

c h a r g i n g e m i s s i o n s f rom t h e s h e d e x h a u s t d u c t d u r i n g t h e

s t u d y . F o r t h e 3 -minu te "peak" p e r i o d s d u r i n g p a r t i c u l a t e

s a m p l i n g , t h e a v e r a g e o p a c i t y was found t o r a n g e f rom 40

t o 60 p e r c e n t . The t h i r d p a r t i c u l a t e s a m p l i n g p e r i o d

- I

- 18 - !.

r e s u l t e d i n a n a v e r a g e o p a c i t y wh ich e x c e e d e d t h a t o f t h e

o t h e r two s a m p l i n g p e r i o d s .

.,

,.

2 . 7 . 3 P e r c e n t o f Doors L e a k i n g

F o r p a r t i c u l a t e s a m p l i n g d a y s , c o k e - s i d e oven d o o r

l e a k a g e was found t o v a r y f r o m 27 t o 6 9 p e r c e n t on B a t t e r y

No. 1 and f rom 39 t o 64 p e r c e n t on B a t t e r y No. 2 . Push-

s i d e d o o r l e a k a g e f o r b o t h b a t t e r i e s was found t o be less

t h a n t h a t o f c o k e - s i d e d o o r l e a k a g e and was l e s s v a r i a b l e .

2 .8 P r o c e s s and E m i s s i o n s C o r r e l a t i o n s

L i n e a r c o r r e l a t i o n t e c h n i q u e s w e r e a t t e m p t e d b u t r e v e a l e d

n o s i g n i f i c a n t r e l a t i o n s h i p b e t w e e n t h e c o n t i n u o u s f i l t e r a b l e

p a r t i c u l a t e e m i s s i o n f a c t o r s o r t h e f i l t e r a b l e p a r t i c u l a t e

p u s h - o n l y e m i s s i o n f a c t o r s a n d a v e r a g e d e g r e e o f g r e e n n e s s o r

a v e r a g e o p a c i t y . F u r t h e r , n o s t a t i s t i c a l l y s i g n i f i c a n t

r e l a t i o n s h i p s were found be tween c o n t i n u o u s f i l t e r a b l e p a r t i c u -

l a t e e m i s s i o n f a c t o r s a n d n e t c o k i n g t i m e o r a v e r a g e f l u e tem-

p e r a t u r e . The s m a l l s ample s i z e , h o w e v e r , l i m i t e d t h e s e n s i -

t i v i t y o f t h e s t a t i s t i c a l a n a l y s e s i n t h e s e c a s e s .

F o r t h e p a r t i c l e s i z i n g s a m p l e s , no l i n e a r c o r r e l a t i o n was

a p p a r e n t be tween v a r i a t i o n s i n s i z e d i s t r i b u t i o n s f o r e a c h o f

t h e s a m p l e s and t h e g r e e n n e s s o f t h e p u s h . I n a d d i t i o n , no

s i g n i f i c a n t c o r r e l a t i o n was a p p a r e n t b e t w e e n p a r t i c l e s i z e and

n e t c o k i n g t i m e . A g a i n , h o w e v e r , t h e s m a l l s ample s i z e l i m i t e d

t h e s e n s i t i v i t y o f t h e s t a t i s t i c a l t e c h n i q u e .

Both peak o p a c i t y a n d g r e e n n e s s w e r e found t o be v e r y h i g h l y

c o r r e l a t e d w i t h n e t c o k i n g t i m e , minus a c o n s t a n t o f 1000 min-

u t e s , when t h e r e c i p r o c a l o f e a c h o f t h e v a l u e s was u s e d . I n

- 19 - addition, peak opacity and greenness were each very highly

correlated with flue temperature.

A highly significant statistical relationship was apparent

between the degree of greenness and the opacity of the exhaust

duct emissions. This relationship characterized opacity as a

function of the logarithm of greenness.

i

,

2.9 Representativeness of Process and Shed Conditions

In order to document that the measured results were repre-

sentative of Battery No. 1's actual emissions during normal pro-

duction, six criteria for comparison were established. On the

basis of these criteria, all samples obtained during this study

were found to be taken during generally representative process

and shed conditions. Only three minor deviations from the

criteria were observed during the more than 300 observations

used to establish representativeness.

-

- 20 -

h

3.0 PROCESS DESCRIPTION AND OPERATIONS

3.1 P r o c e s s D e s c r i p t i o n

Be th lehem S t e e l C o r p o r a t i o n o p e r a t e s a b y - p r o d u c t m e t a l l u r g i c a l

coke m a n u f a c t u r i n g f a c i l i t y a t i t s B u r n s Harbor p l a n t i n C h e s t e r t o n ,

I n d i a n a . T h i s o p e r a t i o n i n c l u d e s a d e s t r u c t i v e d i s t i l l a t i o n p r o -

c e s s , g e n e r a l l y t e rmed " c o k i n g , " t h a t o c c u r s when c o a l is h e a t e d

i n a n a t m o s p h e r e o f low oxygen c o n t e n t . By-p roduc t o r g a n i c com-

pounds , g e n e r a t e d d u r i n g t h e c o k i n g , a r e r e c o v e r e d f rom t h e coke -

oven o f f - g a s e s . The m a i n p r o d u c t , d e - g a s i f i e d c o a l , commonly known

a s "coke , " is a c r i t i c a l r aw m a t e r i a l u sed i n t h e p r o d u c t i o n of

i r o n . L*I The b y - p r o d u c t c o k i n g p r o c e s s o c c u r s i n a "coke b a t t e r y , "

a s e r i e s o f c o n t i g u o u s , r e c t a n g u l a r , r e f r a c t o r y - l i n e d o v e n s . A t

t h e Burns H a r b o r p l a n t , two coke b a t t e r i e s , e a c h c o n t a i n i n g 8 2

o v e n s , a r e p o s i t i o n e d e n d - t o - e n d (See F i g u r e 3 . 1 - 1 ) . E a c h o v e n ,

20 f e e t t a l l , 18 i n c h e s w i d e ( a v e r a g e w i d t h ; t h e oven i s a c t u a l l y

t a p e r e d ) , a n d 5 0 - f e e t l o n g , is c a p a b l e o f p r o d u c i n g a b o u t 24.5

t o n s o f coke p e r push . A t t h e b e g i n n i n g o f a c o k i n g c y c l e , c o a l

is c h a r g e d (dumped) t h r o u g h p o r t s in t h e t o p o f e a c h oven . Subse -

q u e n t l y , e a c h p o r t is s e a l e d and h e a t is a p p l i e d t o t h e o v e n t o

m a i n t a i n a t e m p e r a t u r e o f 2300 t o 2450°F. About 18 h o u r s l a t e r , a t

t h e end o f t h e c o k i n g c y c l e , t h e i n c a n d e s c e n t coke i s pushed f r o m

t h e oven w i t h a m e c h a n i c a l ram i n t o a s p e c i a l l y - d e s i g n e d r a i l r o a d

c a r , c a l l e d a "quench car . ' ' The l o a d of h o t coke i n t h e q u e n c h c a r

is s u b s e q u e n t l y f l o o d e d w i t h w a t e r a t t h e q u e n c h i n g s t a t i o n .

The l a r g e number o f o v e n s on e a c h b a t t e r y makes i t p o s s i b l e

t o a v e r a g e 4.5 p u s h e s p e r h o u r , u t i l i z i n g t h e same e q u i p m e n t f o r

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c h a r g i n g t h e c o a l t o e a c h oven . D u r i n g t h e c o k i n g c y c l e , t h e

oven i s s e a l e d on b o t h e n d s w i t h r e f r a c t o r y - l i n e d d o o r s w h i c h

a r e l o c k e d i n t o p l a c e j u s t p r i o r t o o v e n c h a r g i n g . The d o o r s

a r e t h e n removed j u s t p r i o r t o p u s h i n g t h e c o k e f r o m t h e oven .

E m i s s i o n s f rom t h e c o k e o v e n s c a n o c c u r t h r o u g h o u t t h e i

c y c l e f r o m a r o u n d t h e s e a l e d d o o r s ("door l e a k s " ) , a s w e l l a s

a t t h e end o f t h e c y c l e when t h e c o k e i s pushed f rom t h e o v e n

( " p u s h i n g " ) . The d u r a t i o n o f t h e c o k e p u s h i n g o p e r a t i o n s p h a s e

o f t h e oven c y c l e is b r i e f , l a s t i n g a b o u t 45-90 s e c o n d s ( a p p r o x -

i m a t e l y 30 s e c o n d s f o r c o k e - p u s h i n g e m i s s i o n s and 15 t o 6 0 s e c -

o n d s f o r q u e n c h c a r movement e m i s s i o n s ) . N e v e r t h e l e s s , emis -

s i o n s d u r i n g t h i s b r i e f p e r i o d c a n b e v e r y c o p i o u s . L

The e m i s s i o n s g e n e r a t e d f r o m t h e c o k e s i d e o f B a t t e r y No. 1

a t t h e Burns H a r b o r p l a n t f r o m d o o r l e a k a g e and c o k e p u s h i n g s r e

p r e d o m i n a n t l y c a p t u r e d b y a s e m i - e n c l o s e d s t r u c t u r e t e r m e d t h e

"shed ." A s c h e m a t i c o f t h i s e n c l o s u r e i a p r e s e n t e d i n F i g u r e

3.1-2. The s h e d i s d e s i g n e d t o c a p t u r e t h e s e e m i s s i o n s , w h i c h

e x h i b i t s i g n i f i c a n t t h e r m a l r i s e , and e x h a u s t them t h r o u g h t h e

d u c t l o c a t e d a t t h e s h e d ' s a p e x . T h i s m e c h a n i c a l l y - e x h a u s t e d ,

c o k e - s i d e s h e d is a c a n o p y - t y p e hood t h a t is a b o u t 400 f e e t

l o n g and e n c l o s e s a vo lume o f a b o u t 225 ,000 c u b i c f e e t . De-

s p i t e t h e d e s i g n , f u g i t i v e e m i s s i o n s e s c a p e t h i s e n c l o s u r e on

b o t h e n d s , a s shown i n F i g u r e s 3 .1-2 and 3.1-3. The s o u r c e

t e s t i n g p e r f o r m e d d u r i n g t h i s p r o j e c t was d e s i g n e d t o m e a s u r e

t o t a l c o k e - s i d e e m i s s i o n s . T h e r e f o r e , m e a s u r e m e n t s were made

o f t h e e m i s s i o n s c o l l e c t e d and e x h a u s t e d t h r o u g h t h e d u c t a s

w e l l a s t h e f u g i t i v e e m i s s i o n s f rom t h e s h e d . T h e s e f u g i t i v e

e m i s s i o n s w e r e documented a s t h e y r e l a t e d t o c o k e b a t t e r y and

s h e d o p e r a t i n g p a r a m e t e r s . A d d i t i o n a l l y , t h e s t u d y documented

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t h e " d u s t f a l l " r a t e s w i t h i n t h e s h e d and a t s i m i l a r p o s i t i o n s

on t h e u n s h e d d e d B a t t e r y No. 2 ( s e e F i g u r e 3 .1 -1 ) .

3 .2 R e p r e s e n t a t i v e n e s s o f P r o c e s s and Shed C o n d i t i o n s 3

Because i t c a n n o t b e a s sumed ( w i t h o u t d o c u m e n t a t i o n ) t h a t

measu red r e s u l t s a r e r e p r e s e n t a t i v e o f t h e a c t u a l e m i s s i o n s o f c

a s o u r c e , i t was n e c e s s a r y t o : (1) d e f i n e t h o r o u g h l y t h e ob -

j e c t i v e ( ~ ) o f t h e t e s t p r o g r a m p r i o r t o d e v e l o p i n g t h e t e s t '

p r o t o c o l ; ( 2 ) i d e n t i f y s p e c i f i c a l l y t h e p r o c e s s , c o n t r o l d e v i c e ,

t e s t , and a n a l y t i c a l c o n d i t i o n s r e q u i r e d t o a c h i e v e t h e o b j e c -

t i v e ( ~ ) ; ( 3 ) d e f i n e , i n a d v a n c e o f t e s t i n g , t h e a c c e p t a b l e

r a n g e f o r e a c h p a r a m e t e r ; and ( 4 ) document t h a t t h e r e q u i r e d

c o n d i t i o n s w e r e m a i n t a i n e d d u r i n g t h e t e s t p e r i o d .

3 . 2 . 1 C r i t e r i a f o r Compar i son

B e f o r e t h e r e s u l t s p r e s e n t e d i n t h i s r e p o r t c o u l d

b e c o n s i d e r e d r e p r e s e n t a t i v e o f n o n - t e s t p e r i o d o p e r a t i o n s ,

i t was n e c e s s a r y t o document t h a t a l l r e l e v a n t p r o c e s s and

o p e r a t i o n a l c o n d i t i o n s f o r t e s t and s p e c i f i c n o n - t e s t

p e r i o d s w e r e a c c e p t a b l y " s i m i l a r . " The c r i t e r i o n f o r a c -

c e p t a b l y s i m i l a r d a t a w a s a r b i t r a r i l y d e f i n e d a s + 1 0 p e r -

c e n t o f t h e a v e r a g e t y p i c a l o p e r a t i n g c o n d i t i o n s .

-

4

F u r t h e r , t o more c l e a r l y d e f i n e t h e t e r m i n o l o g y r e -

g a r d i n g c o k e - p u s h i n g o p e r a t i o n s , t h e f o l l o w i n g d e f i n i t i o n s

w e r e f o r m u l a t e d :

A t y p i c a l o p e r a t i n g c o n d i t i o n s : e x t r e m e l y i n f r e q u e n t

m a j o r p r o c e s s c h a n g e s (or u p s e t s ) .

T y p i c a l o p e r a t i n g c o n d i t i o n s : any p r o c e s s o p e r a t i n g

c o n d i t i o n s n o t a t y p i c a l .

~-

- 26 -

.,

r

Abnormal o p e r a t i n g c o n d i t i o n s : a n y t y p i c a l

o p e r a t i n g c o n d i t i o n s d u r i n g wh ich n e t c o k i n g t i m e

is o u t s i d e t h e no rma l n e t c o k i n g t i m e o r d u r i n g

w h i c h a n y c o k e - p u s h i n g s t o p p a g e g r e a t e r t h a n 30

m i n u t e s d u r a t i o n o c c u r s .

Normal o p e r a t i n g c o n d i t i o n s : a n y t y p i c a l o p e r a t i n g

c o n d i t i o n s n o t a b n o r m a l .

T h e r e f o r e , " abnorma l" and "norma l" o p e r a t i n g c o n d i t i o n s a r e com-

p l e m e n t a r y s u b s e t s w i t h i n t h e c a t e g o r y " t y p i c a l " o p e r a t i n g

c o n d i t i o n s .

A f t e r a p r e l i m i n a r y a s s e s s m e n t of t h e p a r a m e t e r s g i v e n i n

T a b l e 3.2.1, i t was d e t e r m i n e d t h a t some of t h e p r o c e s s v a r i a -

b l e s were n e a r l y c o n s t a n t ( A s k a n i a v a l v e p r e s s u r e , a v e r a g e d a i l y

oven c r o s s - w a l l t e m p e r a t u r e , e t c . ) w h i l e many o t h e r s ( s u c h a s

n e t c o k i n g t i m e ) were n o t c o n s t a n t w i t h t i m e . A d d i t i o n a l l y ,

b a s e d upon t h e e f f e c t o f a g i v e n p a r a m e t e r upon t h e s h e d e x h a u s t

d u c t o p a c i t y and t h e p a r t i c u l a t e e m i s s i o n r a t e s r e p o r t e d f rom

e a r l i e r s o u r c e t e s t s a t o t h e r coke -oven f a c i l i t i e s , M r . P a l e y

(U.S. EPA) and Mr. Powal s ( C l a y t o n E n v i r o n m e n t a l C o n s u l t a n t s ,

I n c . ) d e c i d e d t o l i m i t t h e t e s t i n g of t h e b a t t e r y ' s c o k e - s i d e

e m i s s i o n s t o p e r i o d s when t h e c o n d i t i o n s were m a i n t a i n e d w i t h i n

t h e r a n g e s g i v e n be low:

.r,.*

1. Ne t c o k i n g t i m e o f 1 7 - 1 / 4 t o 18-1/2 h o u r s

(1035-1110 m i n u t e s ) , 2 . Coke-push ing c y c l e d u r a t i o n up t o 30 m i n u t e s

l o n g ( w i t h i n + 1 0 p e r c e n t ) , - 3. C o a l f e e d r a t e of 35 t o n s ( w e t ) p e r c h a r g e

( w i t h i n - + 10 p e r c e n t ) ,

TABLE 3.2.1 PERTINENT PARAMETERS Burns H a r b o r P l a n t

Beth lehem S t e e l C o r p o r a t i o n Ches t e r t o n , I n d i a n a

March 3 -7 , 1 9 7 5

- 27 -

Coking Time ( m i n u t e s ) Net Minimum

Average D a i l y Cross-Wal l T e m p e r a t u r e s (OF)

Coal Feed r a t e (wet pounds c h a r g e d p e r oven) Feed r a t e ( d r y pounds c h a r g e d p e r oven) Chemica l and p h y s i c a l a n a l y s e s ( a v e r a g e v a l u e s )

Average U n d e r f i r e Gas Flow (lo3 CFH)

Coke Average r a t e o f p r o d u c t i o n ( t o n s p e r d a y ) P h y s i c a l a n a l y s e s ( a v e r a g e v a l u e s )

Coke Oven Ga5 Average r a t e o f p r o d u c t i o n (lo3 CFH) Chemica l a n a l y s e s

Average A s k a n i a Valve P r e s s u r e (mm H20)

B a t t e r y Operd t i o n s Number and l o c a t i o n of empty o v e n s Door m a i n t e n a n c e S c h e d u l e d / u n s c h e d u l e d downtime Use o f e x p e r i m e n t a l d o o r s O c c u r r e n c e o f a t y p i c a l o r a b n o r m a l e v e n t s

Coke-Pushing O p e r a t i o n C lock t i m e f o r e a c h oven pushed D u r a t i o n o f e a c h push ( s e c o n d s ) D u r a t i o n o f e a c h push c y c l e ( m i n u t e s ) G r e e n n e s s o f coke-oven p u s h

Shed E v a l u a t i o n Average e x h a u s t r a t e ( a c t u a l c u b i c f e e t p e r m i n u t e ) Fan c u r v e s Amperage and v o l t a g e used D u r a t i o n r e q u i r e d t o c l e a r t h e peak ( p u s h ) e m i s s i o n s

Oven Door Leak O b s e r v a t i o n s Coke s i d e P u s h - s i d e and chuck d o o r s

L o c a l S u r f a c e Wind C o n d i t i o n s Average s p e e d (mph) and d i r e c t i o n ( d e g r e e s ) d u r i n g t e s t p e r i Speed (mph) and d i r e c t i o n ( d e g r e e s ) d u r i n g n o n - t e s t p e r i o d P e r s i s t e n c e a t 45" and + 6 mph o f winds -

Shed D e s i g n P a r a m e t e r s ( s i z e , s h a p e )

..,

I:

,od

C l a y t o n E n v i r o n m e n t a l C o n s u l t a n t s , I n c .

.I

~

4 .

5 .

6.

7 .

- 2a -

Coke p r o d u c t i o n r a t e o f 24 t o n s p e r p u s h

( w i t h i n - + 10 p e r c e n t ) ,

A v e r a g e p u s h i n g r a t e o f 4 . 5 p u s h e s p e r h o u r

( w i t h i n - + 10 p e r c e n t ) ,

C o a l a n a l y s i s ( a v e r a g e p e r c e n t c o a l m o i s t u r e

and BTU/lb c o a l ) c o m p a r a b l e t o t h a t o f t y p i -

c a l l y c h a r g e d c o a l ( w i t h i n - + 1 0 p e r c e n t ) , a n d

Shed e v a c u a t i o n r a t e of 3 0 0 , 0 0 0 SCFM ( w i t h i n

+ 1 0 p e r c e n t ) . - 3 . 2 . 2 C o n d i t i o n s d u r i n g S a m p l i n g P e r i o d s

On t h e , b a s i s o f t h e c r i t e r i a p r e s e n t e d i n S e c t i o n

3 . 2 . 1 , a l l s a m p l e s o b t a i n e d d u r i n g t h i s s t u d y were t a k e n

d u r i n g g e n e r a l l y r e p r e s e n t a t i v e p r o c e s s a n d s h e d c o n d i t i o n s

by i n t e r r u p t i n g s a m p l i n g d u r i n g a b n o r m a l and a t y p i c a l

p e r i o d s . T a b l e s 3 . 2 . 2 - 1 and 3 .2 .2-2 i n d i c a t e t h e a v e r a g e

v a l u e s a n d / o r t h e r a n g e of v a l u e s f o r e a c h o f t h e s i x

c r i t e r i a d i s c u s s e d p r e v i o u s l y f o r p e r i o d s b e f o r e , d u r i n g ,

and a f t e r p a r t i c u l a t e s a m p l i n g . E x c e p t i o n s t o t h e f i r s t

o f t h e six c r i t e r i a o c c u r r e d on t h e two o c c a s i o n s when

Oven 1 9 1 was p u s h e d , i . e . , d u r i n g P a r t i c u l a t e T e s t s 1 a n d

3 . The n e t c o k i n g t i m e f o r t h i s oven was a p p r o x i m a t e l y

1400 m i n u t e s d u e t o i t s p o s i t i o n a t t h e end o f t h e b a t t e r y ;

t h i s i s t y p i c a l f o r Oven 1 9 1 . T h e r e was a l s o a s i n g l e

e x c e p t i o n t o t h e s e c o n d c r i t e r i o n d u r i n g P a r t i c u l a t e T e s t

No. 2 , when a 3 9 - m i n u t e i n t e r v a l b e t w e e n p u s h e s o c c u r r e d .

T h e s e t h r e e o b s e r v a t i o n s w e r e t h e o n l y d e v i a t i o n s , h o w e v e r ,

f r o m t h e s i x c r i t e r i a ( e n c o m p a s s i n g o v e r 300 o b s e r v a t i o n s )

- 29 - TABLE 3.2.2-1

t i o n R a t e ( t o n s / p u s h )

Average Number o f Push e s / h o u r

Average C o a l M o i s t u r e C o n t e n t ( p e r c e n t )

Average BTU/lb C o a l

COMPARISON OF KEY PROCESS PARAMETERS (BATTERY NO. 1)

Burns H a r b o r P l a n t Be th lehem S t e e l C o r p o r a t i o n

C h e s t e r t o n , I n d i a n a March 3-7, 1975

I T i m e P e r i o d

4.4 4.5 4.9 4.5 4.5

6.6 6.9 7.3 7.3 6.7

1162 1160 1160 1166 1166

Average Shed Evacua- t i o n R a t e (DSCFM)

295 , 000 268,000 - (BSC D a t a )

C l a y t o n E n v i r o n m e n t a l C o n s u l t a n t s , I n c .

- 3 0 - TABLE 3.2.2-2

COMPARISON OF KEY PROCESS PARAMETERS (BATTERY NO. 2)

B u r n s H a r b o r P l a n t B e t h l e h e m S t e e l C o r p o r a t i o n

Ches t e r t o n , I n d i a n a March 3-7, 1976

B e f o r e S a m p l i n g

T i m e P e r i o d I

D u r i n g S a m p l i n g Days

(March 3-7, 1 9 7 5 )

P a r a m e t e r

Average Net Cok ing T i m e 1 1028 ( M i n u t e s )

1003

Average Wet C o a l Feed R a t e (Ton 8 / C h a r g e )

Range o f T i m e Between 4 - 1 2 2 6-56 P u s h e s ( M i n u t e s ) I

34.8 35.0

A v e r a g e C o a l M o i s t u r e C o n t e n t ( P e r c e n t )

Average B T U / l b c o a l

I 25.4 I . A v e r a g e Coke P r o d u c t i o n R a t e ( T o n s / P u s h )

6.7 6.9

1 2 8 1 1207

25.6

I I I

Average Number o f P u s h e s / h o u r 4.8 4.9

A f t e r S a m p l i n g

1003

5-66

35.3

25.8

4.9

7.3

1227

C l a y t o n E n v i r o n m e n t a l C o n s u l t a n t s , I n c .

- 3 1 -

e s t a b l i s h e d f o r r e p r e s e n t a t i v e s a m p l i n g .

The i n t e n t t o e n s u r e t h a t these t e s t s were r e p r e s e n t a t i v e

o f t y p i c a l o p e r a t i o n s a t t h e maximum p r o d u c t i o n r a t e r e q u i r e d

t h e s a m p l i n g t o b e d e l a y e d s e v e r a l mon ths d u r i n g a c o a l s t r i k e ., u n t i l t h e p l a n t had b e e n a t t y p i c a l o p e r a t i n g c o n d i t i o n s f o r

a t l e a s t o n e week. Two d a y s b e f o r e t h e s c h e d u l e d i n i t i a t i o n

o f t h e e m i s s i o n t e s t s , t h e p l a n t i n c u r r e d a m a j o r u p s e t ( c o a l

f e e d c o n v e y o r breakdown) wh ich c a u s e d a few a d d i t i o n a l d a y s of

a t y p i c a l o p e r a t i n g c o n d i t i o n s . T h i s r e s u l t e d i n a s e c o n d d e l a y

i n t h e t e s t s c h e d u l e . A t h i r d d e l a y o c c u r r e d when, a f t e r a p r e -

l i m i n a r y t r a v e r s e , t h e s t a c k g a s e x h a u s t r a t e was found t o b e

somewhat u n d e r t h e c r i t e r i o n m e n t i o n e d i n I t e m 7 a b o v e . However,

a f t e r a s s u r a n c e s were g i v e n b y Be th lehem S t e e l C o r p o r a t i o n

p e r s o n n e l t h a t t h e e x h a u s t r a t e was a t maximum and r e p r e s e n t a -

t i v e c o n d i t i o n s , s a m p l i n g commenced. D u r i n g s a m p l i n g , t h e

s t a c k g a s e x h a u s t r a t e w a s n e a r l y w i t h i n t h e + 1 0 p e r c e n t c r i -

t e r i o n . A few p l a n t e q u i p m e n t p r o b l e m s d i d c a u s e a b n o r m a l

o p e r a t i o n s d u r i n g t he t e s t p e r i o d . However, s i n c e t h e e f f e c t s

of s u c h i r r e g u l a r i t i e s p a s s e d r a p i d l y , t h e r e s p o n s e t o s u c h

e v e n t s w a s o n l y t o i n t e r r u p t t h e t e s t s u n t i l t h e p r o c e s s and

s h e d c o n d i t i o n s were a g a i n o p e r a t i n g n o r m a l l y .

e

-

- The p r o c e d u r e u s e d t o e n s u r e t h e s e r e p r e s e n t a t i v e p rocese

and s h e d c o n d i t i o n s i n c l u d e d d o c u m e n t i n g , by c o m p a r i s o n t o d a t a

f r o m o t h e r o p e r a t i n g p e r i o d s , t h e f a c t t h a t t h e s a m p l i n g p e r i o d . was r e p r e s e n t a t i v e o f t y p i c a l o p e r a t i o n s . A l l p r o c e s s o p e r a -

t i o n s and shed p e r f o r m a n c e d a t a a c q u i r e d f o r t h e s a m p l i n g p e r i o d

and f o r p e r i o d s p r i o r t o a n d f o l l o w i n g t h e s a m p l i n g p e r i o d a r e

p r o v i d e d i n A p p e n d i c e s A-0 (Volumes 2 - 4 ) .

- 3 2 - 3 . 3 I d e n t i f i c a t i o n o f P o s s i b l e N o r m a l i z i n g F a c t o r s

S o u r c e s a m p l i n g and a n a l y t i c a l d a t a m u s t f r e q u e n t l y be

n o r m a l i z e d u s i n g p r o c e s s o r p e r f o r m a n c e d a t a t o o b t a i n a more

r e p r e s e n t a t i v e c h a r a c t e r i z a t i o n o f e m i s s i o n s due t o v a r y i n g

4, o p e r a t i o n a l c o n d i t i o n s . P r i o r t o , d u r i n g , and s u b s e q u e n t t o . t h i s s t u d y , p o t e n t i a l l y s i g n i f i c a n t p r o c e s s , s h e d , m e t e o r o -

l o g i c a l and e m i s s i o n d a t a were o b t a i n e d and r e c o r d e d by

b o t h B e t h l e h e m S t e e l C o r p o r a t i o n a n d EPA p e r s o n n e l . Those

.q

.,

p a r a m e t e r s c o n s i d e r e d a s p o s s i b l e n o r m a l i z i n g f a c t o r s w e r e

g i v e n i n T a b l e 3 . 2 . 1 .

Two r a t i o n a l e s were c o n s i d e r e d i n t h e s e l e c t i o n o f a

n o r m a l i z i n g f a c t o r :

a . E m i s s i o n d a t a s h o u l d b e n o r m a l i z e d w i t h r e f e r e n c e t o

some p r o c e s s p a r a m e t e r t o r e f l e c t t h e a v e r a g e ( o r

"normal") p a r t i c u l a t e e m i s s i o n r a t e .

b . E m i s s i o n d a t a s h o u l d n o t b e n o r m a l i z e d w i t h r e f e r e n c e

t o some p r o c e s s p a r a m e t e r t o r e f l e c t t h e maximum

e m i s s i o n r a t e ( a s s u m i n g c o n t i n u o u s p u s h i n g and n o t

j u s t one p u s h a b o u t e v e r y 13 m i n u t e s ) .

To r e f l e c t a c t u a l o p e r a t i n g c o n d i t i o n s , t h e f i r s t o f t h e s e two

a l t e r n a t i v e s was c h o s e n . F u r t h e r , and t r a d i t i o n a l l y , e m i s s i o n

r a t e s h a v e b e e n compared and n o r m a l i z e d t o t h e p r o c e s s i n p u t

r a t e , b a s e d i n p a r t upon t h e c o n c e p t o f a m a t e r i a l b a l a n c e .

F i n a l l y , i n t h i s c a s e t h e p r o c e s s i n p u t r a t e ( c o a l f e e d r a t e )

i s a d i r e c t l y m e a s u r a b l e q u a n t i t y . T h u s , p a r t i c u l a t e e m i s s i o n s

d a t a h a v e b e e n n o r m a l i z e d w i t h r e s p e c t t o c o a l f e e d r a t e t o

f a c i l i t a t e i n t e r p r e t a t i o n o f t h e p a r t i c u l a t e e m i s s i o n s d a t a ,

Such n o r m a l i z e d p a r t i c u l a t e e m i s s i o n r a t e s a r e p r e s e n t e d i n

S e c t i o n s 2 . 0 and 5 . 0 .

- ,.

- 3 3 -

4 . 0 SAMPLING A N D A N A L Y T I C A L METHODS

7.

I 1

.1

4 . 1 T e s t P r o t o c o l

I n g e n e r a l , t h e s a m p l i n g , s a m p l e h a n d l i n g , c a l i b r a t i o n ,

and a n a l y s e s p e r f o r m e d i n t h i s s t u d y i n c o r p o r a t e d t h e l a t e s t ,

mos t w e l l - e s t a b l i s h e d m e t h o d s a v a i l a b l e , i n c l u d i n g t h o s e

p r o m u l g a t e d by EPA and ASTM. T h e r e were s e v e r a l i n s t a n c e s ,

h o w e v e r , a s d e s c r i b e d i n s u b s e q u e n t p a r a g r a p h s , when m o d i f i e d

o r n o v e l t e c h n i q u e s were r e q u i r e d i n o r d e r t o e n s u r e r e p r e s e n t a -

t i v e r e s u l t s . I n a l l c a s e s , a method was s e l e c t e d o n l y i f i t

s a t i s f i e d t h e f o l l o w i n g c r i t e r i a - q u e s t i o n s :

1. Would t h e s a m p l i n g p r o c e d u r e q u a n t i t a t i v e l y c a t c h t h e

a n a l y t e o f i n t e r e s t ?

2 . Would t h e a n a l y t e of i n t e r e s t be c a u g h t i n a medium o r

media i n wh ich i t c o u l d b e s e p a r a t e d and q u a n t i f i e d ?

3 . Would t h e a n a l y t i c a l p r o c e d u r e c h a r a c t e r i z e a l l of t h e

c o n t a m i n a n t s p e c i e s o f i n t e r e s t w h i l e m i n i m i z i n g t h e

n e c e s s a r y number o f t e s t s ?

T h i s s t u d y was d e s i g n e d t o i n v e s t i g a t e t h o r o u g h l y t h e

t y p i c a l , n o r m a l e m i s s i o n s p r o d u c e d on t h e coke s i d e o f B a t t e r y

No. 1, i n c l u d i n g a n y f u g i t i v e e m i s s i o n s t h a t m i g h t o c c u r . T h u s ,

t h e a p p r o a c h t o m e e t i n g t h i s o b j e c t i v e was t o d e f i n e b o t h t h e

p r o c e s s c o n d i t i o n s and s a m p l i n g a n d a n a l y t i c a l m e t h o d s r e q u i r e d

t o m e a s u r e t h e e m i s s i o n s d u r i n g t y p i c a l , n o r m a l o p e r a t i o n

c o n d i t i o n s . S a m p l i n g and a n a l y t i c a l p r o c e d u r e s were t h e r e f o r e

s p e c i f i c a l l y d e s i g n e d a r o u n d t h e p r o c e s s and c a p t u r e s y s t e m

c h a r a c t e r i s t i c s t o p r o v i d e t h e maximum amount o f i n f o r m a t i o n

w i t h a r e a s o n a b l e e x p e n d i t u r e o f e f f o r t . A d d i t i o n a l l y , much

- 34 - c a r e was t a k e n t o e n s u r e t h a t s a m p l i n g o c c u r r e d o n l y d u r i n g

"norma l" o p e r a t i o n s ( a s a g r e e d m u t u a l l y by B e t h l e h e m S t e e l

p e r s o n n e l a n d M e s s r s . Bloom a n d P a l e y o f t h e DSSE, U.S. E P A ;

s e e S e c t i o n 3.2).

A f t e r i n i t i a l d i s c u s s i o n s w i t h p e r s o n s f rom Be th lehem

S t e e l C o r p o r a t i o n and C l a y t o n E n v i r o n m e n t a l C o n s u l t a n t s , I n c . , c

.. i t was m u t u a l l y a g r e e d t h a t t h e U.S. EPA would be r e s p o n s i b l e

f o r a c q u i s i t i o n o f a l l p r o c e s s d a t a f rom B e t h l e h e m S t e e l

C o r p o r a t i o n w h i l e C l a y t o n E n v i r o n m e n t a l C o n s u l t a n t s would be

r e s p o n s i b l e f o r a c q u i s i t i o n o f t h e s a m p l i n g and a n a l y t i c a . 1

i n f o r m a t i o n . The EPA was a l s o r e s p o n s i b l e f o r v i s i b l e e m i s s i o n s

d a t a a c q u i s i t i o n , i n c l u d i n g s t i l l a n d m o t i o n p h o t o g r a p h y .

A c c o r d i n g l y , t h e t h r e e p a r t i e s ( B e t h l e h e m S t e e l C o r p o r a t i o n ,

C l a y t o n E n v i r o n m e n t a l C o n s u l t a n t s , and t h e U.S. EPA) worked

c l o s e l y t o g e t h e r t o a c q u i r e t h e i n f o r m a t i o n n e c e s s a r y t o docu-

ment t h e r e s u l t s o f t h i s s t u d y . The t y p e s o f p r o c e s s d a t a

a c q u i r e d w e r e r e v i e w e d i n T a b l e 3 . 2 . 1 (and a r e p r e s e n t e d i n

.. .. ._..._ .. , % . .. ,. . . - . . - .---...-- '. L..&"..6.. ', , *I..*&= L L L r L y y - 0 "; o ' a u ~ y L L * ~ ~ a,.; - . a l l y L I C c a I

d a t a a c q u i r e d were g i v e n i n T a b l e 1 .0 -1 .

4 . 2 L o c a t i o n o f S a m p l i n g P o i n t s

" C o n t i n u o u s " p a r t i c u l a t e s a m p l i n g was c o n d u c t e d i n t h e

s h e d e x h a u s t d u c t shown i n F i g u r e 3 . 1 - 2 . The s a m p l i n g p l a n e

l o c a t i o n and s a m p l i n g p o i n t o c a t i o n s me t t h e minimum r e q u i r e -

m e n t s s p e c i f i e d i n "Method 1 - Sample and V e l o c i t y T r a v e r s e s

f o r S t a t i o n a r y S o u r c e s , U.S. EPA, I n - h o u s e D r a f t , 7 - 1 8 - 7 4 "

(Append ix P , Volume 5). The s a m p l i n g p l a n e was l o c a t e d 3 . 2

d u c t d i a m e t e r s downs t r eam o f t h e n e a r e s t p o t e n t i a l d i s t u r b a n c e

- 35 -

and 1 . 2 d u c t d i a m e t e r s u p s t r e a m o f t h e s t a c k s . The two

s a m p l i n g p o r t s w e r e l o c a t e d 90 d e g r e e s a p a r t i n t h e c i r c u l a r

d u c t . The d u c t w a s s u b d i v i d e d i n t o 48 e q u a l a r e a s ; t h e 4 8

s a m p l i n g p o i n t s a r e shown i n F i g u r e 4 .2 -1 .

P e a k p a r t i c u l a t e s a m p l i n g was c o n d u c t e d t h r o u g h t h e same

two p o r t s u s e d f o r c o n t i n u o u s p a r t i c u l a t e s a m p l i n g . I n o r d e r

t o a v o i d p r o b e c r o s s o v e r , h o w e v e r , w h i l e o b t a i n i n g c o n t i n u o u s

and peak s a m p l e s c o n c u r r e n t l y , t h e d u c t was s u b d i v i d e d i n t o

20 e q u a l a r e a s f o r p e a k p a r t i c u l a t e s a m p l i n g . The 2 0 peak

s a m p l i n g p o i n t s a r e shown i n F i g u r e 4.2-2.

.. . .-.

.--_ .-

Each o f t he f o u r p a r t i c l e - s i z i n g s a m p l e s was t a k e n a t a

s i n g l e s a m p l i n g p o i n t a c c e s s e d t h r o u g h t h e h o r i z o n t a l p o r t .

These f o u r t e s t s a r e i d e n t i f i e d i n t h e summary t a b l e s and g r a p h s

by t h e s a m p l i n g - p o i n t numbers shown i n F i g u r e 4 .2-3 .

A l l o t h e r s a m p l e s , s u c h a s s u l f u r o x i d e s a n d s a m p l e s

c o l l e c t e d i n sodium h y d r o x i d e , w e r e t a k e n a t a s i n g l e p o i n t 30

i n c h e s i n t o t h e d u c t t h r o u g h t h e t o p p o r t . T h i s s a m p l i n g p o i n t

i s i n d i c a t e d i n F i g u r e 4 .2-3 .

4 . 3 C o n t i n u o u s P a r t i c u l a t e E m i s s i o n s f rom Shed E x h a u s t Duct

" C o n t i n u o u s " p a r t i c u l a t e s a m p l i n g was c o n d u c t e d t o o b t a i n

a n e s t i m a t e o f t h e " c o n t i n u o u s " p a r t i c u l a t e e m i s s i o n s f rom t h e

c o k e - s i d e s h e d and i n c l u d e d c o k e - p u s h i n g o p e r a t i o n e m i s s i o n s ,

d o o r l e a k s , and r e s i d u a l e m i s s i o n s f rom p r e v i o u s p u s h e s . T h e s e

s a m p l e s were t a k e n by s a m p l i n g c o n t i n u o u s l y e x c e p t when o p e r a -

t i o n a l u p s e t s or downt ime o c c u r r e d of g r e a t e r t h a n 3 0 - m i n u t e s

d u r a t i o n .

_- -- - - -- . - -

C o n t i n u o u s p a r t i c u l a t e s a m p l i n g was c o n d u c t e d i n a c c o r d a n c e

w i t h t h e t h e n - m o s t - r e c e n t d r a f t s of EPA Methods 1 , 2 , and 5

~-

- 36 -

/ Ladder

S amp 1 i n g P o i n t

\ I * I2

C P l a t f o r m

/ * 9 d3

V e r t i c e 1

P o s i t i o n

1 " L

3 4 5 6 7 8 9

10 1 1 12 1 3 1 4 15

H o r i z o n t a 1

I

E x h a u e t d u c t d i a m e t e r : 138" 3.2 e x h a u s t , d u c t d i a m e t e r s downst ream of

1.2 e x h a u s t d u c t d i a m e t e r s u p s t r e a m o f - ~ P Y O C + n n t o n t i n 1 A i c t l * r h r , . n ~ o

n e a r e s t p o t e n t i a l d i s t u r b a n c e

16 17 1 8 1 9 20

22 23 2 4

7 1

FIGURE 4.2-1

SCHEMATIC D I A G R A M OF S A M P L I N G P O I N T L O C A T I O N S FOR " C O N T I N U O U S " PARTICULATE SAMPLES

Burns H a r b o r P l a n t Be th lehem S t e e l C o r p o r a t i o n

Che s t e r t on, I n d i a na March 3-7, 1 9 7 5

Loea t i o n s

.- D i s t a n c e ( i n c h e s ) *

1-112 4-318 7 - 5 1 8

1 0 - 7 / 8 14-112 1 8 - 3 / 1 6

2 6 - 3 / 4 2 2 - 3 / 1 6

31-314 37-112 44- 9 1 16 5 4 - 5 / 1 6 8 3 - 1 / 1 6 9 3 - 7 / 1 6

100-112 1 0 6 - 1 / 4 111-114 1 1 5 - 1 3 / 1 6 1 1 8 - 1 3 / 1 6 1 2 3 - 1 / 2 1 7 7 - 1 I R

1 3 0 - 3 / 8 133-518 1 3 6 - 1 / 2

C l a y t o n E n v i r o n m e n t a l C o n s u l t a n t s , I n c .

Y

- 37 -

L a d d e r

/'*

T o p P l a t f o r m

n I - I., ,

* I O

I

;-

.I

V e r t i c a 1

\. P l a t f o r m

E x h a u s t d u c t d i a m e t e r : 138"

i

,i /

,/

3 . 2 e x h a u s t d u c t d i a m e t e r s d o w n s t r e a m o f n e a r e s t

1 . 2 e x h a u s t d u c t . d i a m e t e r s u p s t r e a m o f n e a r e s t p o t e n t i a 1 d i s t u r b a n c e

p o t e n t i a 1 d i s t u r b a n c e

S a m p l i n g P o i n t L o c a t i o n s

D i s t a n c e Pos i t i o n ( i n c h e s )

FIGURE 4 .

1 2 3 4 5 6 7 8 9

10

- 2

SCHEMATIC D I A G R A M OF SAMPLING POINT LOCATIONS FOR "PEAK" PARTICULATE SAMPLES

B u r n s H a r b o r P l a n t B e t h l e h e m S t e e l C o r p o r a t i o n

Ches t e r t o n , I n d i a n a March 3 - 7 , 1 9 7 5

3 - 7 / 1 6 11- 5 / 1 6 20 -1 /8 3 1 - 3 / 1 6 4 7 - 3 / 1 6 90-13116

106-13116

126-11 /16 134- 9/ 1 6

117-718

C l a y t o n E n v i r o n m e n t a l C o n s u l t a n t s , I n c .

L a d d e r

E x h a u s t d u c t d i a m e t e r : 138” 3 . 2 e x h a u s t d u c t d i a m , e t e r s downs t r eam o f

.1.2 e x h a u s t d u c t d i a m e t e r s u p s t r e a m of n e a r e s t p o t e n t i a l d i s t u r b a n c e

n e a r e s t p o t e n t i a l d i s t u r b a n c e

1 1 ///-

/‘ i

2 34-112 3 103- 112 4 128- 3 14

O t h e r Samples

D i s t a n c e V e r t i c a l r o s i c i o n ( L I I C L L e b )

. . .

1 30

,-

F I G U R E 4.2-3

SCHEMATIC DIAGRAM OF SAMPLING P O I N T LOCATIONS FOR ALL SAMPLES EXCEPT PARTICULATE

B u r n s H a r b o r P l a n t B e t h l e h e m S t e e l C o r p o r a t i o n

C h e s t e r t o n , I n d i a n a March 3-7, 1975

- I

C l a y t o n E n v i r o n m e n t a l C o n s u l t a n t s , I n c .

. I - 3 9 - ( F i n a l I n - h o u s e D r a f t s 7-18-74, 7-21-74, a n d 7-25-74, r e s p e c -

t i v e l y ) . C o p i e s o f t h e s e me thods a r e p r e s e n t e d i n A p p e n d i c e s

P - R , r e s p e c t i v e l y (Volume 5 ) . I t s h o u l d b e n o t e d t h a t t h i s

d r a f t o f EPA Method 5 a l l o w s t h e f i l t e r i n t h e s a m p l i n g t r a i n

t o be m a i n t a i n e d a t a t e m p e r a t u r e o t h e r t h a n " a b o u t 250'F" and

a l s o a l l o w s m e a s u r e m e n t of t h e i m p i n g e r c a t c h . B e c a u s e n o

change i n p a r t i c u l a t e c o n c e n t r a t i o n was a n t i c i p a t e d by s a m p l i n g

a t a n y t e m p e r a t u r e up t o t h a t o f t h e s t a c k g a s , t h e t e m p e r a t u r e

of t h e f i l t e r f o r t h e c o n t i n u o u s p a r t i c u l a t e t e s t s was m a i n t a i n e d .

a t t h e a v e r a g e s t a c k g a s t e m p e r a t u r e , wh ich r a n g e d f rom 84 t o 98 'F .

D e t a i l e d d e s c r i p t i o n s o f t h e s a m p l i n g and a n a l y t i c a l me thods

a r e g i v e n i n Append ix S (Volume 5). The p a r t i c u l a t e s a m p l e s

were a n a l y z e d f o r t h e m a t e r i a l s i n d i c a t e d i n T a b l e 1 . 0 - 1 .

4.4 D e t e r m i n a t i o n o f Peak P a r t i c u l a t e E m i s s i o n P e r i o d

T h i s s t u d y was d e s i g n e d t o i n d e p e n d e n t l y m e a s u r e b o t h t h e

c o n t i n u o u s p a r t i c u l a t e e m i s s i o n r a t e a n d t h e i n t e r m i t t e n t

p a r t i c u l a t e e m i s s i o n r a t e d u r i n g t h e c o k e - p u s h i n g o p e r a t i o n ,

i . e . , peak p a r t i c u l a t e e m i s s i o n r a t e . To a s c e r t a i n t h e a v e r a g e

d u r a t i o n o f t h e p e r i o d o f peak p a r t i c u l a t e e m i s s i o n s f rom t h e

e x h a u s t d u c t , two s e t s of f i l t e r o b s c u r i t y , o p a c i t y , a n d

t e m p e r a t u r e m e a s u r e m e n t s were a c q u i r e d . T h e s e d a t a a r e p r e -

s e n t e d i n F i g u r e s 4.4-1 and 4.4-2 a n d T a b l e 4.4. The t i m e s

i n d i c a t e d on F i g u r e s 4.4-1 and 4.4-2 r e p r e s e n t t h e t i m e i n t e r v a l

s i n c e t h e b e g i n n i n g o f t h e p u s h d u r i n g wh ich t h e s a m p l e was

t a k e n . E v a l u a t i o n o f t h e s e d a t a i n d i c a t e s t h a t t h e peak p a r t i c -

u l a t e e m i s s i o n p e r i o d was a p p r o x i m a t e l y t h r e e m i n u t e s . The

method o f d a t a a n a l y s i s is d e s c r i b e d i n d e t a i l i n Append ix T

(Volume 5).

m

It

.,

- 4 0 - F I G U R E 4 . 4 - 1

SEQUENTIAL F I L T E R O B S C U R I T Y TEST ON FEBRUARY 24, 1 9 7 5

Burns Harbor P lant Bethlehem S t e e l Corporation

C h e s t e r t o n , Indiana March 3 - 7 , 1975

0 -15 s e c .

2

30-45 s e c .

6

60-75 s e c .

7

120-135 s e c . 150-165 s e c . -

180-195 .set.

9 10

240-255 s e c .

13

0 650-665 s e c .

270-285 s e c .

11 . ...

, I> ,. ,', ,,.' ..... . . .~ , . . ,

. . .A,'. , . . . : ..:

. , . .:

. .

540-555 s e c .

90-105 s e c .

a

210-225 8ec .

(--J . * \ . .. .. , . ., . . , .. . ' . . . -.;

... . . . . . > . >> , ,I , .: .:. . *' , ' . , L .: , '. . _.... '..

I . .. . .

. . . . . . . . , ? . . . 2 : . . . . .

. .. . .

570-585 s e c .

Clayton Environmental C o n s u l t a n t s , Inc.

+

- 41 - FIGURE 4 .4 -2

S E Q U E N T I A L FILTER O B S C U R I T Y T E S T O N MARCH 3 , 1975

Burns H a r b o r P l a n t Be th lehem S t e e l C o r p o r a t i o n

C h e s t e r t o n , I n d i a n a March 3-7 , 1975

.0 -30 . . s e c .

5.

13 5 - . 1 5 O--ee'C.

?.

., - 255- ....... 270 ,.sec.

,Q, 13 ..

2 . 3 4

45-6 0 ..sdc. 7 5 - 9 0 s e c . 105-120 s e c .

./.. 6 . .

10 .............. ,,A' --.

>. .. .:, : ., . . . . . . . . . . . . . . . . . . . . . . . . . .

. .

285-'300 s e c .

7 ...

195-210 s e c .

11

360-375 s e c .

8

2 2 5 - 240 '6 e c . 1 2

420-435 s e c .

C l a y t o n E n v i r o n m e n t a l C o n s u l t a n t s , I n c . 480-495 s e c .

TABLE 4 -4

DETERMINATION OF PEAK PARTICULATE EMISSION PERIOD FROM THE EXHAUST DUCT

Burns H a r b o r P l a n t Be th lehem S t e e l C o r p o r a t i o n

C h e s t e r t o n , I n d i a n a March 3 - 7 , 1975

T e s t Number

1 (2-24-75 a t 1 3 4 5 )

2 (3-3-75 a t 1158)

~ ~~

F i l t e r Number

1 2 3 4 5 6 7 8 9

10 11 1 2 13

1** 2 3 4 5 6 7 8 9

1 0 11 1 2 . 13

0 3 0 60 90

120 150 180 210 240 270 540 570 6 50

0 45 7 5

105 135 165 1 9 5 225 255 285 360 420 480

S t a c k Temp.

( O F ) - * * * * * * * * * * * * *

75 120 145 125 105 100

95 8 3 8 0 78 78 78 78

Aver a g e Plume

O p a c i t y (%)

1 5 50 50 50 50 40 25 20 20 20 1 5 1 5 1 5

20 8 0 6 0 40 25 20 20 2 0 20 20 20 20 20

* No d a t a a c q u i r e d ** 30-second d u r a t i o n f i l t e r o b s c u r i t y sample

C l a y t o n E n v i r o n m e n t a l C o n s u l t a n t s , I n c .

9

c

h.

z

- 4 3 -

4.5 Peak P a r t i c u l a t e E m i s s i o n s f rom Shed E x h a u s t Duct

"Peak" p a r t i c u l a t e s a m p l i n g was p e r f o r m e d I___~__ t o d e t e r m i n e . -- - ---_ t h e i n d i v i d u a l c o n t r i b u t i o n o f p u s h i n g o p e r a t i o n e m i s s i o n s . -- t o

t h e a v e r a g e , c o n t i n u o u s p a r t i c u l a t e e m i s s i o n r a t e f rom t h e

u n c o n t r o l l e d c o k e - s i d e s h e d . P e a k p a r t i c u l a t e s a m p l e s were

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

-- . _ _

a c q u i r e d u s i n g EPA Method 2 ( F i n a l In-House D r a f t , 7-21-74) and

v a r i a t i o n s of EPA Methods 1 and 5 ( F i n a l In-House D r a f t , 7-18-74

and 7-25-74, r e s p e c t i v e l y ) . T h e s e me thods a r e i n c l u d e d i n

A p p e n d i c e s P-R (Volume 5).

The m a j o r m o d i f i c a t i o n t o E P A Method 5 was t h a t t h e peak

p a r t i c u l a t e e m i s s i o n s were m e a s u r e d o n l y d u r i n g t h e e v a c u a t i o n

of t h e s h e d d u r i n g and i m m e d i a t e l y a f t e r coke p u s h i n g , i . e . ,

f o r t h r e e m i n u t e s o u t o f a p p r o x i m a t e l y 13 m i n u t e s . T h u s , e a c h 7

peak p s r t i c u l a t e s ample c o n s i s t e d of i n t e r m i t t e n t l y s a m p l i n g

20 i n d i v i d u a l coke -oven p u s h e s w i t h t h e p r o b e s t a t i o n a r y duri-ng - e a c h p u s h . I t s h o u l d be n o t e d t h a t , i n g e n e r a l , t h e peak and ------- c o n t i n u o u s s a m p l e s were a c q u i r e d c o n c u r r e n t l y .

Because t h e peak p a r t i c u l a t e e m i s s i o n t e s t s w e r e c o n d u c t e d

on a n i n t e r r u p t i b l e b a s i s ( i . e . , s a m p l i n g f o r t h r e e m i n u t e s and

t h e n s t o p p i n g f o r a b o u t 10 m i n u t e s , t h e n s a m p l i n g a g a i n ) , t h e

f i l t e r t e m p e r a t u r e was m a i n t a i n e d j u s t a b o v e t h e d e w p o i n t of

t h e s t a c k g a s e s .

The peak p a r t i c u l a t e s a m p l e s were a n a l y z e d f o r t h e m a t e r i a l s

i n d i c a t e d i n T a b l e 1 . 0 - 1 . A l l s a m p l i n g and a n a l y t i c a l me thods

a r e p r e s e n t e d i n Append ix S (Volume 5).

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

P a r t i c l e s i z e t e s t s were p e r f o r m e d t o d e f i n e t h e d i s t r i -

b u t i o n o f p a r t i c l e s e n t e r i n g a p o t e n t i a l c o n t r o l d e v i c e . S i n c e

- 44 -

p r e v i o u s coke p u s h i n g s t u d i e s h a v e u s e d t h e c a s c a d e i m p a c t i o n

m e t h o d , t h e s i z i n g d e t e r m i n a t i o n s w e r e p e r f o r m e d u s i n g a n

o u t s i d e - t h e - s t a c k B r i n k c a s c a d e i m p a c t o r . Each o f t h e f o u r

p a r t i c l e s i z e s a m p l e s were t a k e n a t a d i f f e r e n t s i n g l e p o i n t ,

e a c h r e p r e s e n t i n g a n e q u a l a r e a , ( a t a n i s o k i n e t i c r a t e ) _I

b e c a u s e a c c u r a t e c a l c u l a t i o n of t h e a e r o d y n a m i c d i a m e t e r o f

e a c h i m p a c t i o n s t a g e i s i m p o s s i b l e i f t h e s a m p l i n g r a t e v a r i e s

d u r i n g s a m p l i n g ( s u c h a s would r e s u l t f rom m a i n t a i n i n g s n

i s o k i n e t i c r a t e w h i l e t r a v e r s i n g a number o f p o i n t s ) . I n

a d d i t i o n , t h e p a r t i c u l a t e c o n c e n t r a t i o n f o r e a c h of t h e f o u r

p a r t i c l e s i z e s a m p l e s was c a l c u l a t e d f o r c o m p a r i s o n t o t h e

f i l t e r a b l e p a r t i c u l a t e c o n c e n t r a t i o n s r e s u l t i n g f rom 3 - m i n u t e

peak p a r t i c u l a t e s a m p l e s . The s a m p l i n g and a n a l y t i c a l me thods

f o r p a r t i c l e s i z i n g a r e p r e s e n t e d i n Append ix U (Volume 5 ) .

- -

4.7 E m i s s i o n s o f O t h e r M a t e r i a l s

A l a r g e number of a d d i t i o n a l e m i s s i o n m e a s u r e m e n t s were

mar l - A . . r i n o tho p n ~ r r , = nf t h e s t u d y . A c o m ~ l e t e r o s t e r of t h e

e m i s s i o n s m e a s u r e d i s p r e s e n t e d i n T a b l e 1 . 0 - 1 , a n d t h e p u r p o s e

f o r o b t a i n i n g e a c h o f t h e s e m e a s u r e m e n t s i s s p e c i f i e d i n

T a b l e 1 . 0 - 2 .

-

S u l f u r d i o x i d e and s u l f u r i c a c i d m i s t ( s u l f u r t r i o x i d e ) . ,

s a m p l e s w e r e a c q u i r e d and a n a l y z e d a c c o r d i n g t o U.S. EPA

R e f e r e n c e Method 8 . Hydrogen s u l f i d e s a m p l e s were a c q u i r e d and

a n a l y z e d a c c o r d i n g t o U.S. EPA R e f e r e n c e Method 11. T h e s e

me thods a r e i n c l u d e d i n A p p e n d i c e s V a n d W (Volume 5 ) , r e s p e c t i v e l y .

S a m p l i n g a n d a n a l y t i c a l m e t h o d s f o r a l l o t h e r c o n t a m i n a n t s

m e a s u r e d d u r i n g t h e s t u d y a r e n o t c o v e r e d by E P A - s t a n d a r d i z e d

- 45 -

p r o c e d u r e s . O t h e r s t a n d a r d m e t h o d s , s u c h a s ASTM m e t h o d s , were

u s e d a s much a s p o s s i b l e . A l l s a m p l i n g p r o c e d u r e s were r e v i e w e d

and a c c e p t e d by M r . Louis P a l e y , P . E . , DSSE, U.S. EPA, p r i o r t o

t h e i r u s e . S i m i l a r l y , a l l a n a l y t i c a l p r o c e d u r e s w e r e r e v i e w e d

and a c c e p t e d by M r . Mark A n t e l l , DSSE, U.S. EPA, p r i o r t o t h e i r

u s e . A c o m p l e t e d e s c r i p t i o n of e a c h o f t h e s e s a m p l i n g and

a n a l y t i c a l m e t h o d s is g i v e n i n A p p e n d i c e s X - B B (Volume 5 ) .

4 .8 D u s t f a l l Measuremen t s

In o r d e r t o a s s e s s t h e i m p a c t o f t h e c o k e - s i d e s h e d upon

p a r t i c u l a t e d e p o s i t i o n , d u s t f a l l m e a s u r e m e n t s were made using

t h e g e n e r a l p r i n c i b l e s o u t l i n e d i n ASTM Method D-1739-70.

Measuremen t s were t a k e n w i t h i n and n e a r t h e c o k e - s i d e s h e d and

a t s i m i l a r l o c a t i o n s on t h e unshedded (No. 2 ) coke b a t t e r y , a s

shown i n F i g u r e 3.1-1. D u s t f a l l s a m p l e b u c k e t s w e r e l o c a t e d

a t a p p r o x i m a t e l y e q u i v a l e n t p o s i t i o n s o n b o t h b e n c h e s a b o u t 13

f e e t a b o v e g r a d e . Near t h e s h e d w a l l (on t h e f a r s i d e o f t h e

quench c a r t r a c k s ) , t h e d u s t f a l l b u c k e t s w e r e e l e v a t e d a b o u t 1 0

f e e t a b o v e g r a d e on t h e f a r s i d e o f t h e r a i l r o a d t r a c k s . Each

d u s t f a l l b u c k e t w a s c a r e f u l l y p o s i t i o n e d t o a v o i d , a s much a s

p o s s i b l e , i n c i n e r a t i o n f rom f a l l i n g coke , d e f o r m a t i o n , o r o t h e r

means o f d e s t r u c t i o n . In a d d i t i o n , e i g h t p a i r s o f d u s t f a l l

s a m p l e s w e r e a c q u i r e d a b o u t t h r e e f e e t a b o v e g r a d e t o a s s e s s t h e

p r e c i s i o n o f t h e t e c h n i q u e .

A d u s t f a l l m e a s u r e m e n t made i n t h e a m b i e n t a i r u s u a l l y

r e q u i r e s a p e r i o d o f 3 0 d a y s . B e c a u s e d u s t f a l l l e v e l s a r e

o r d e r s o f m a g n i t u d e h i g h e r i n t h e i m m e d i a t e v i c i n i t y o f a coke

b a t t e r y t h a n in a m b i e n t a i r , i t was o n l y n e c e s s a r y t o e x p o s e

- 46 - t h e d u s t f a l l b u c k e t s f o r p e r i o d s of h o u r s i n t h e s e t e s t s .

I t s h o u l d be n o t e d t h a t t h e s e t t l e d d u s t i n e a c h c a n was

f i l t e r e d d u r i n g t h e l a b o r a t o r y a n a l y s i s t h r o u g h a No. 18 mesh

s c r e e n (1-mm s q u a r e ) t o remove l a r g e chunks o f f a l l e n c o k e .

I n a d d i t i o n , s e l e c t e d d u s t f a l l s a m p l e s were a n a l y z e d f o r pH,

a c e t o n e - s o l u b l e c o n t e n t , and c y c l o h e x a n e - s o l u b l e c o n t e n t . The

s a m p l i n g and a n a l y t i c a l t e c h n i q u e s a r e summar ized i n Append ix

CC (Volume 5).

y1

.-

4 .9 S u b j e c t i v e a n d V i s u a l E m i s s i o n P a r a m e t e r s

4 . 9 . 1 Degree o f G r e e n n e s s

The s e m i - q u a n t i t a t i v e measu remen t s c a l e used t o

e s t i m a t e v i s u a l l y t h e r e l a t i v e q u a n t i t y o f p a r t i c u l a t e

m a t t e r r e l e a s e d d u r i n g a coke -oven p u s h i s t e rmed " d e g r e e

o f g r e e n n e s s . " I n a p p l y i n g t h i s t e c h n i q u e , t h e d u r a t i o n

o f t h e c o k e - p u s h i n g o p e r a t i o n was e s t i m a t e d and d i v i d e d

i n t o t h i r d s . The amount of v i s i b l e p a r t i c u l a t e g e n e r a t e d

d u r i n g e a c h t h i r d was e s t i m a t e d by m e n t a l l y i n t e g r a t i n g

t h e q u a n t i t y o f p a r t i c u l a t e g e n e r a t e d and r e c o r d i n g t h e

v a l u e on a s c a l e of one t o f o u r ( " v e r y l i t t l e " e m i s s i o n s t o

" c o p i o u s " amoun t s o f e m i s s i o n s , r e s p e c t i v e l y ) . Each o b s e r -

v a t i o n r e p r e s e n t e d t h e t o t a l o b s c u r i t y c a u s e d by t h e e m i s -

s i o n s f rom b o t h t h e f a l l i n g c o k e and t h e coke i n t h e quench

c a r . The r e s u l t i n g numbers f o r e a c h t h i r d o f each coke -oven

push w e r e t h e n summed t o g i v e a s e m i - q u a n t i t a t i v e measu re

o f e m i s s i o n s g e n e r a t e d f rom e a c h c o k e - o v e n p u s h on a s c a l e

o f t h r e e t o 1 2 . In a d d i t i o n , t h e same o b s e r v e r r e c o r d e d

t h e a c t u a l d u r a t i o n of t h e c o k e - p u s h i n g o p e r a t i o n w i t h a

..

i

<. 1 -

- 47 -

s t o p w a t c h . A s econd e s t i m a t e o f t h e amount o f e m i s s i o n s

r e l e a s e d , t h e p r o d u c t of t h e sum o f t h e r a t i n g s and t h e

d u r a t i o n of t h e p u s h , was a l s o d e t e r m i n e d . The d e t a i l e d

method f o r d e t e r m i n a t i o n of t h e d e g r e e of g r e e n n e s s o f a

coke -oven p u s h is g i v e n in A p p e n d i x DD (Volume 5).

4 . 9 . 2 O p a c i t y o f Shed E x h a u s t

A l t h o u g h F i g u r e 3 . 1 - 2 shows t h e s h e d e x h a u s t d u c t

w i t h one e x i t s t a c k , i n f a c t , two s t a c k s were u s e d t o d i s -

c h a r g e t h e e m i s s i o n s from t h e s h e d e x h a u s t d u c t d u r i n g t h e

s t u d y . F u r t h e r , a t h i r d e x h a u s t s t a c k e x i s t e d b u t was

s e a l e d c o m p l e t e l y d u r i n g t h i s s t u d y , , ' O p a c i t y d a t a were

a c q u i r e d by U.S. EPA p e r s o n n e l f o r t h e two f u n c t i o n a l s t a c k s

using EPA Method 9 . These v a l u e s were a v e r a g e d and t h e r e -

a f t e r t r e a t e d m a t h e m a t i c a l l y a s if t h e r e were o n l y a s i n g l e

s t a c k . A copy o f t h e method is c o n t a i n e d in Append ix E E

(Volume 5 ) .

I ,

4 . 9 . 3 P e r c e n t o f Doors L e a k i n g

S i n c e d o o r e m i s s i o n s a p p e a r e d t o be p r e d o m i n a n t l y

i n d e p e n d e n t of e i t h e r c o k e - p u s h i n g o r quench c a r p a r t i c u -

l a t e e m i s s i o n s , a n o b s e r v a t i o n t e c h n i q u e t h a t r e c o r d e d t h e

q u a n t i t y o f oven d o o r s l e a k i n g v i s i b l y d u r i n g a s h o r t - t e r m

o b s e r v a t i o n p e r i o d was d e v e l o p e d o n - s i t e . T h e s e o b s e r v a -

t i o n s y i e l d e d a n e s t i m a t e o f t h e p e r c e n t of c o k e - s i d e d o o r s

l e a k i n g . S i m i l a r o b s e r v a t i o n s were made and r e s u l t s were

c a l c u l a t e d f o r t h e push s i d e of t h e c o k e b a t t e r y t o document

g e n e r a l p r o c e s s c o n d i t i o n s . A d e t a i l e d d e s c r i p t i o n o f t h e

b a s i c method is p r o v i d e d i n Append ix FF (Volume 5 ) .

- 4 8 - 4 . 9 . 4 V i s u a l E s t i m a t e s of F u g i t i v e E m i s s i o n s

The s a m p l i n g p r o g r a m d e v e l o p e d t o e v a l u a t e t h e

s h e d l e a k a g e r a t e ( f u g i t i v e p a r t i c u l a t e e m i s s i o n s ) i n c l u d e d

o n - s i t e e v a l u a t i o n o f o p a c i t y and t h e s u b s e q u e n t u s e o f

p h o t o g r a p h s o f t h e s e e m i s s i o n s . O p a c i t y o b s e r v a t i o n s

w e r e made by EPA p e r s o n n e l u n d e r s e v e r a l d i f f e r e n t p r o c e s s ,

w i n d , and s h e d l e a k - r a t e c o n d i t i o n s u s i n g EPA Method 9

( s e e A p p e n d i x E E , Volume 5 ) . Twen ty - seven o b s e r v a t i o n s

o f t h e s h e d end l e a k a g e were made d u r i n g r a n d o m l y - s e l e c t e d ,

c o m p l e t e p u s h i n g c y c l e s on f o u r d a y s . The o b s e r v a t i o n s

w e r e made w h i l e l o o k i n g d i a g o n a l l y t h r o u g h t h e p lume , a s

c l o s e a s p o s s i b l e t o t h e p o i n t o f e m i s s i o n ( s h e d e n d ) .

I

._

.. -

Both 16-mm b l a c k - a n d - w h i t e and c o l o r m o v i e s , and

35-mm c o l o r s t i l l s w e r e t a k e n r andomly d u r i n g t h e f u g i t i v e

p a r t i c u l a t e s a m p l i n g p e r i o d s and d u r i n g o t h e r i n s t a n c e s of

end a n d t o p s i d e s h e d l e a k a g e . T h e s e p h o t o g r a p h s were u s e d

p r i m a r i l y t o e s t i m a t e t h e c r o s s - s e c t i o n a l a r e a ( i . e . ,

h e i g h t a n d w i d t h ) o f t h e f u g i t i v e plume e m a n a t i n g f rom t h e

e n d s a n d s i d e o f t h e s h e d .

4 . 1 0 F u g i t i v e P a r t i c u l a t e E m i s s i o n s f rom t h e Shed

I n a d d i t i o n t o t h e o p a c i t y d a t a and p h o t o g r a p h s d i s c u s s e d . i n S e c t i o n 4 . 9 . 4 , t h e s a m p l i n g p rogram f o r f u g i t i v e e m i s s i o n s

i n c l u d e d t h e measu remen t o f f u g i t i v e p a r t i c u l a t e c o n c e n t r a t i o n s

a t t h r e e p o i n t s o f l e a k a g e f rom t h e s h e d . Each s a m p l e was t a k e n

d u r i n g ( v i s u a l l y d e t e r m i n e d ) "peak" e m i s s i o n p e r i o d s . These

s a m p l e s w e r e c o l l e c t e d u s i n g a 47-mm d i a m e t e r g l a s s - f i b e r f i l t e r ,

a c a l i b r a t e d l i m i t i n g o r i f i c e , and a l e a k l e s s d i a p h r a g m pump.

- 49 -

'i-

A v a n e - a x i a l anemomete r and a s t o p w a t c h .were u s e d t o e s t i m a t e

t h e e x h a u s t g a s v e l o c i t y . The s a m p l i n g r a t e f o r e a c h s a m p l e

was h e l d c o n s t a n t u s i n g t h e c r i t i c a l o r i f i c e i n t h e s a m p l i n g

t r a i n . The c r i t i c a l o r i f i c e was s i z e d i n i t i a l l y t o t h e

a v e r a g e a n t i c i p a t e d v e l o c i t y b a s e d upon p r e l i m i n a r y v a n e - a x i a l

anemometer m e a s u r e m e n t s made i n t h e v a r i o u s a r e a s o f f u g i t i v e

p a r t i c u l a t e e m i s s i o n s . Due t o s p a t i a l a n d t e m p o r a l v a r i a t i o n s

i n v e l o c i t y , h o w e v e r , t h e s e s a m p l e s w e r e a c q u i r e d a n i s o k i n e t i c a l l y .

A d e t a i l e d d e s c r i p t i o n o f t h e s a m p l i n g a n d a n a l y t i c a l m e t h o d s i s

p r e s e n t e d i n A p p e n d i x G G (Volume 5 ) .

T h e s e s h o r t - t e r m ( a p p r o x i m a t e l y 1 - 1 / 4 m i n u t e s ) f u g i t i v e

p a r t i c u l a t e m e a s u r e m e n t s were t h e n e x t r a p o l a t e d t o a c o n t i n u o u s ,

f u g i t i v e p a r t i c u l a t e e m i s s i o n r a t e e s t i m a t e . T h i s w a s a c c o m p l i s h e d

by u s i n g t h e s h e d l e a k o p a c i t y d a t a ( c o n v e r t e d t o " a t t e n u a t i o n

c o e f f i c i e n t s " ( 3 ) ) a s t h e b a s i s f o r e x t r a p o l a t i o n f rom t h e s h o r t -

t e r m b a s i s t o a c o n t i n u o u s b a s i s . T h i s was p o s s i b l e b e c a u s e i t

h a s b e e n shown t h a t mass e m i s s i o n s c a n be c o r r e l a t e d w i t h t h e

a t t e n u a t i o n c o e f f i c i e n t f o r c o a l d u s t . ( 3 ) A f u l l d e s c r i p t i o n

o f t h e t e c h n i q u e i s p r o v i d e d i n A p p e n d i x HH (Volume 5 ) .

Ll.,

4 . 1 1 C a l i b r a t i o n , Q u a l i t y A s s u r a n c e , a n d S a m p l i n g I n t e g r i t y

C h a i n - o f - c u s t o d y p r o c e d u r e s u t i l i z e d d u r i n g t h i s s t u d y w e r e

f o l l o w e d c o n s c i e n t i o u s l y . Each s a m p l e was u n i q u e l y i d e n t i f i e d ,

and a t a l l t i m e s e i t h e r one member o f t h e C l a y t o n t e s t t eam was

w i t h t h e s a m p l e s o r t h e s a m p l e s w e r e l o c k e d s e c u r e l y i n s t o r a g e .

C a l i b r a t i o n s o f a l l i n s t r u m e n t s were p e r f o r m e d b o t h p r i o r

t o and a f t e r t h e s a m p l i n g p e r i o d . The c r i t i c a l o r i f i c e s u s e d

i n t h e f u g i t i v e p a r t i c u l a t e s a m p l i n g were c a l i b r a t e d , e v e n

t h o u g h n o p r o m u l g a t e d a i r p o l l u t i o n r e g u l a t i o n s i n t h e U n i t e d

- 50 - S t a t e s r e q u i r e d c a l i b r a t i o n o f t h e s e d e v i c e s a t t h e t i m e o f

t h e s t u d y . F i n a l l y , t h e s a m p l e h a n d l i n g a n d a n a l y s i s t e c h -

n i q u e s w e r e a p p r o v e d by M r . Mark A n t e l l (DSSE, U.S. EPA) a f t e r

c o n s u l t a t i o n w i t h C l a y t o n p e r s o n n e l . I,

The me thods u s e d f o r i n s t r u m e n t c a l i b r a t i o n i n t h i s s t u d y - a r e p r e s e n t e d i n A p p e n d i x I1 (Volume 5). The c a l i b r a t i o n d a t a - a r e g i v e n i n A p p e n d i x JJ (Volume 5 ) . A l i s t o f t h e s a m p l e s

v o i d e d d u r i n g t h e c o n d u c t o f t h e s t u d y and t h e r e a s o n s f o r v o i d -

i n g them a r e l i s t e d i n A p p e n d i x KK (Volume 5). F i e l d s a m p l i n g

d a t a s h e e t s a r e p r o v i d e d i n A p p e n d i x LL (Volume 5 ) , w h i l e

a n a l y t i c a l d a t a a r e p r e s e n t e d i n A p p e n d i x MM (Volume 5 ) . "Cha in

o f C u s t o d y " p r o c e d u r e s a r e g i v e n i n A p p e n d i x NN (Volume 6 ) ,

and e x a m p l e c a l c u l a t i o n s a r e shown i n A p p e n d i x 00 (Volume 6 ) .

C o p i e s o f a l l c o r r e s p o n d e n c e w i t h B e t h l e h e m S t e e l C o r p o r a t i o n

a r e i n c l u d e d i n Append ix PP (Volume 6 ) . R e s u l t s o f p r e v i o u s

s a m p l i n g by B e t h l e h e m S t e e l C o r p o r a t i o n a t t h e B u r n s H a r b o r

~ l a n t a r e u r e s e n t e d in A n p e n d i u nn ( ~ T o l i r m o 6 ) . . .

I . - 5 1 -

5 . 0 PRESENTATION AND DISCUSSION OF RESULTS

5 . 1 Coke-Side P a r t i c u l a t e E m i s s i o n s

Two t y p e s o f p a r t i c u l a t e s a m p l e s w e r e c o l l e c t e d in t h e

e x h a u s t d u c t f r o m t h e c o k e - s i d e s h e d a t t h e Burns H a r b o r p l a n t .

The f i r s t , t e r m e d " c o n t i n u o u s " p a r t i c u l a t e e m i s s i o n s , s p a n n e d

t h e e n t i r e p e r i o d when p u s h i n g o c c u r r e d , a s w e l l a s t h e i n t e r -

v a l s b e t w e e n p u s h e s . S a m p l i n g c o n t i n u e d d u r i n g t h e s e i n t e r v a l s

u n l e s s p r o c e s s u p s e t s o r downtime e x c e e d e d 30 m i n u t e s .

The s e c o n d t y p e o f s a m p l i n g e s t i m a t e d "peak" p a r t i c u l a t e

e m i s s i o n s f r o m t h e s h e d . T h e s e s a m p l e s were a c q u i r e d by

s a m p l i n g i n t e r m i t k a d t l y d u r i n g t h e p e r i o d s found t o h a v e maxi -

mum v i s i b l e e m i s s i o n s , i . e . , t h e 3 -minu te i n t e r v a l w h i c h

i m m e d i a t e l y f o l l o w e d t h e b e g i n n i n g o f a p u s h . S i n c e b o t h

c o n t i n u o u s and p e a k e m i s s i o n s i n c l u d e d e s s e n t i a l l y t h e same

p u s h e s , t h e two t y p e s o f s a m p l e s w e r e , i n a s e n s e , s i m u l t a n e o u s .

. - -____.

I t s h o u l d b e n o t e d t h a t b o t h t y p e s o f s a m p l e s n e c e s s a r i l y - -_. _- -- ~ - - -- i n c l u d e d q u e n c h c a r e m i s s i o n s w h i l e i t was u n d e r t h e s h e d a n d

d o o r l e a k s , o c c u r r i n g c o n s t a n t l y , a s w e l l a s r e s i d u a l _- . e m i s s i o n s

f rom " o l d p u s h e s ." N e i t h e r t y p e , h o w e v e r , i n c l u d e d t h e

e m i s s i o n s t h a t w e r e f u g i t i v e f r o m t h e s h e d . I t was t h e r e f o r e

n e c e s s a r y t o e s t i m a t e t h e s e f u g i t i v e e m i s s i o n s by a n o t h e r

t e c h n i q u e .

- _- -. --_ -

____.

5 . 1 . 1 C o n t i n u o u s P a r t i c u l a t e E m i s s i o n s f rom t h e E x h a u s t D u c t

The c o n t i n u o u s p a r t i c u l a t e e m i s s i o n s f rom t h e s h e d

-

e x h a u s t d u c t a r e summar ized i n T a b l e 5 . 1 . 1 . These ' v a l u e s

r e p r e s e n t e m i s s i o n s f r o m p u s h i n g , d o o r l e a k s , q u e n c h c a r

- 52 -

e 0 d

L)

- * 1.I 0 U 0 e b

C 0 4 a m d E W

m U m 3

0 d U U m !a

a

- U a M d m 3 m

U m m m d m 0 0 U !a

Y

m U

h

m C 0 .r( m m d 0 m 3 3 m U

; 0

U 0 VI

m

3

m m 4 e m U

a, m 111 v

m C 0 d m

*I

m QJ U m 3

0 d Y I4 m a

m

E

a

; d U d M 7

W

m a 1 3 0 c d

U 0 c 0 P

v1 m

3 a

$ W W m c H *

,

w 0

e 0 U

1.I PI a a m 0 1 a 0 1.I a 111 d

m 3 0 0

W 0

c 0 U

m r. 0

U m c U

a 0 U m d a c d

m m a C 0 .d Y m 1.I 0

"

- . m U c - m U 3 - a m c 0 U

3 m U C

C 0 Y h m 4 U

- 53 -

h

movement, a n d t h e r e s i d u a l e m i s s i o n s f rom p r e v i o u s p u s h e s ,

b u t i n h e r e n t l y d o n o t i n c l u d e f u g i t i v e e m i s s i o n s f rom t h e

she.d. The e m i s s i o n f a c t o r s f o r b o t h f i l t e r a b l e a n d t o t a l

p a r t i c u l a t e a r e r e l a t i v e l y c o n s i s t e n t among t h e m s e l v e s

a n d a v e r a g e 0 . 7 8 and 0.80 pound o f p a r t i c u l a t e p e r t o n o f

d r y c o a l fed, o r 0 . 9 9 a n d 1 . 0 pound o f p a r t i c u l a t e p e r t o n

o f c o k e p r o d u c e d , r e s p e c t i v e l y . A more c o m p l e t e summary

o f s a m p l i n g t i m e s , s ampled v o l u m e s , c o n c e n t r a t i o n s , a n d

e m i s s i o n r a t e s c a n b e f o u n d i n 7 A p p e n d i x R R (Volume 6). _/----- 1

5.1.2 F u g i t i v e P a r t i c u l a t e E m i s s i o n s

J u s t p r i o r t o c o m m e n c e m e n t , , ~ f t h e s t u d y , f u g i t i v e

p a r t i c u l a t e e m i s s i o n s w e r e o b s e r v e d t o b e l e a k i n g f rom

t h e s h e d a t t h e f o u r p o s i t i o n s shown i n F i g u r e 3.1-2: 1)

t h e n o r t h end o f t h e s h e d , 2) t h e s o u t h end o f t h e s h e d ,

3) t h e A s k a n i a v a l v e s , a n d 4 ) t h e b o u n d a r y b e t w e e n t h e

s h e d and t h e coke b a t t e r y . The A s k a n i a v a l v e s and s h e d -

b a t t e r y b o u n d a r y l e a k a g e w e r e o b s e r v e d t o b e e s s e n t i a l l y

c o n s t a n t , w h i l e t h e e n d s l e a k a g e wen t t h r o u g h a n i n c r e a s -

i n g - d e c r e a s i n g o p a c i t y c y c l e s i m i l a r t o t h a t of t h e

e x h a u s t d u c t e m i s s i o n s . B e c a u s e t h e p r i m a r y g o a l o f t h i s

p r o j e c t was t o m e a s u r e t h e e m i s s i o n s f r o m t h e c o k e s i d e

o f t h e b a t t e r y a n d n o t j u s t f r o m t h e s h e d e x h a u s t d u c t ,

t h e f u g i t i v e p a r t i c u l a t e e m i s s i o n s e s c a p i n g t h e s h e d were

e s t i m a t e d . To a c c o m p l i s h t h i s , a m e a s u r e m e n t t e c h n i q u e

was d e v e l o p e d i n t h e f i e l d t h a t i n c l u d e d s h o r t - t e r m

a n i s o k i n e t i c , f u g i t i v e p a r t i c u l a t e e m i s s i o n m e a s u r e m e n t s .

- 54 -

T a b l e 5.1.2 summar izes t h e r e s u l t s o f t h e s e

m e a s u r e m e n t s . The f u g i t i v e p a r t i c u l a t e c o n c e n t r a t i o n s

r a n g e d f rom 0.002 t o 0.124 g r a i n p e r d r y s t a n d a r d c u b i c

f o o t (gr /DSCF) . T h e s e c o n c e n t r a t i o n s w e r e e x t r a p o l a t e d

t o e s t i m a t e t h e c o n t i n u o u s f u g i t i v e p a r t i c u l a t e e m i s s i o n

r a t e ( 3 ) by t h e m e t h o d o l o g y p r e s e n t e d i n Appendix HH

(Volume 5 ) . The r e s u l t i n g e s t i m a t e was 21.9 pounds of

f u g i t i v e p a r t i c u l a t e p e r h o u r . Based upon a n a v e r a g e

f e e d r a t e d u r i n g c o n t i n u o u s p a r t i c u l a t e s a m p l i n g o f 1 6 1

t o n s o f d r y c o a l p e r h o u r ( s e e T a b l e 5.1.1), t h i s e m i s s i o n

r a t e c o r r e s p o n d s t o a n e m i s s i o n f a c t o r of 0.14 pound of

f i l t e r a b l e p a r t i c u l a t e p e r t o n o f d r y c o a l f e d t o t h e

ovens, o r 0 . 1 7 pound of f i l t e r a b l e p a r t i c u l a t e p e r t o n o f

coke p r o d u c e d .

._cc-

~.

S i n c e t h e s e v a l u e s e s t i m a t e t h e f u g i t i v e f i l t e r a b l e

p a r t i c u l a t e e m i s s i o n s o n a c o n t i n u o u s b a s i s , t h e y may be

r e l a t e d t o t h e c o n t i n u o u s f i l t e r a b l e p a r t i c u l a t e e m i s s i o n s

f rom t h e e x h a u s t d u c t , wh ich a v e r a g e d 0 . 7 8 pound p e r t o n

o f d r y c o a l f e d ( s e e S e c t i o n 5.1.1). The p e r c e n t a g e of

t h e e m i s s i o n s t h a t were f u g i t i v e c a n t h e n be c a l c u l a t e d

a s f o l l o w s :

* 100 = 15% 0.14 0.14 + 0.78

T h u s , a p p r o x i m a t e l y 1 5 p e r c e n t o f t h e f i l t e r a b l e p a r t i c u -

l a t e e m i s s i o n s e s c a p e d f rom t h e s h e d on a c o n t i n u o u s b a s i s .

5.1.3 O v e r a l l C o n t i n u o u s Coke-Side P a r t i c u l a t e E m i s s i o n s

Us ing t h e p a r t i c u l a t e e m i s s i o n s d a t a p r e s e n t e d i n

t h e p r e v i o u s t w o s e c t i o n s , . i t is p o s s i b l e t o e s t i m a t e t h e

1975 Date - 3-5

3-5

3-5

3-5

3-6

3-6

3-5

3-6

3-5

3-6

3-6

3-6

3-5

3-5 -

- 55 - TABLE 5.1.2

MEASURED FUGITIVE PARTICULATE EMISSIONS E S C A P I N G FROM THE SHED

B u r n s H a r b o r P l a n t

C h e s t e r t o n , I n d i a n a March 3-7, 1975

B e t h l e h e m S t e e l C o r p o r a t i o n .

Sample D e s c r i p t i o n

~~

T o p s i d e a t c r o s s o v e r b u t t e r f l y f o r o v e n s 112&113; P u s h i n g o v e n 114

T o p s i d e a t o v e n 112; C h a r g i n g o v e n 114

T o p s i d e a t o v e n 134; C h a r g i n g o v e n 134

T o p s i d e ; Off main a t o v e n 134

Nor th e n d ; P u s h i n g o v e n 105

Nor th end ; P u s h i n g oven 123

N o r t h e n d ; P u s h i n g oven 124

N o r t h e n d ; P u s h i n g o v e n 125

N o r t h e n d ; P u s h i n g o v e n 126

Nor th end P u s h i n g o v e n 183

S o u t h end P u s h i n g o v e n 113

Sou th end P u s h i n g oven 1 8 1

Sou th e n d ; P u s h i n g o v e n 184

Sou th e n d ; P u s h i n g o v e n 191

F u g i t i v e P a r t i c u l a t e

C o n c e n t r a t i o n (gr/DSCF)

0.105

0.002

0.029

0.077

0.124

0.006

0.117

0.022

0.053

0.024

0.017

0.051

0,002

<0.006

V e l o c i t y ( f t /min )

- - 160

151

276

230

- 201

353

221

337

409

171

312

C l a y t o n E n v i r o n m e n t a l C o n s u l t a n t s , I n c .

I

- 5 6 -

o v e r a l l p a r t i c u l a t e e m i s s i o n s e m a n a t i n g f rom t h e coke

s i d e o f t h e s h e d on a c o n t i n u o u s b a s i s . T a b l e 5.1.3 p r e -

s e n t s b o t h t h e c o n t i n u o u s f i l t e r a b l e p a r t i c u l a t e e m i s s i o n s ,

wh ich d o n o t i n c l u d e f u g i t i v e e m i s s i o n s , a n d t h e o v e r a l l

f i l t e r a b l e p a r t i c u l a t e e m i s s i o n s . T h e s e o v e r a l l e m i s s i o n s I

-

i n c l u d e e m i s s i o n s f rom p u s h i n g , d o o r l e a k s , q u e n c h c a r .-

movement u n d e r t h e s h e d , t h e r e s i d u a l f rom p r e v i o u s p u s h e s ,

a n d f u g i t i v e e m i s s i o n s f r o m t h e s h e d , b u t d o n o t i n c l u d e

e m i s s i o n s f rom t h e q u e n c h c a r d u r i n g t r a n s i t o u t s i d e t h e

s h e d .

..

The o v e r a l l e m i s s i o n r a t e s p r e s e n t e d i n T a b l e

5.1.3 h a v e b e e n e s t i m a t e d by a d d i n g t h e a v e r a g e c o n t i n u -

o u s f u g i t i v e e m i s s i o n r a t e d e v e l o p e d i n S e c t i o n 5.1.2 t o

t h e c o n t i n u o u s e m i s s i o n r a t e f o r e a c h p a r t i c u l a t e s a m p l e .

E m i s s i o n f a c t o r s f o r e s t i m a t e d f u g i t i v e e m i s s i o n s were

d e t e r m i n e d by d i v i d i n g t h i s a v e r a g e e m i s s i o n r a t e by t h e

c o a l f e e d r a t e s f o r t h e i n d i v i d u a l s a m p l e s p r e s e n t e d p r e -

v l o u s i y I n r a o i e 3.1.1. ne o v e r a i r e m l s s l o n r a c ~ u r e W T L S

t h e n e s t i m a t e d t o r a n g e f rom 0.89 t o 0.93, and a v e r a g e 0.91

pound o f f i l t e r a b l e p a r t i c u l a t e p e r t o n o f d r y c o a l f e d , o r

1.2 pound o f f i l t e r a b l e p a r t i c u l a t e p e r t o n o f c o k e p r o d u c e d .

5.1.4 Peak P a r t i c u l a t e E m i s s i o n s f rom t h e Shed

T a b l e 5.1.4 p r e s e n t s t h e p e a k p a r t i c u l a t e e m i s s i o n s

m e a s u r e d i n t h e s h e d e x h a u s t d u c t . T h e s e peak e m i s s i o n s

w e r e q u a n t i f i e d by s a m p l i n g d u r i n g o n l y t h e p e r i o d of

g r e a t e s t v i s i b l e e m i s s i o n s , i . e . , t h e f i r s t t h r e e m i n u t e s

of t h e a p p r o x i m a t e l y 1 3 - m i n u t e i n t e r v a l when p u s h i n g

'i

e 0

Y

- 57 -

n, I

h U

m m w m m m 0 0 0

P - m b 4 4 4

0 0 0 . . m e 4 4 4 4

0 0 0 . .

m m m r l 4 4 N N N

b m ' m o m o r l o

\ o m m b b b

0 0 0 . .

m m r l N N N 4 4 4

r l N m

. 0 d H

n m U e m U rl 1 m d 0 0

4 m U

- 5 8 -

U U 3 n U rn 3 d 92 x W

d

0 z w d W U U

2 W m U

c 0

... U al a

- 4l I4 0 U 0 m a C 0 d m W d E W

al U m d

0 d U Y m !&

a

- U L: 00 d

0 0

0 N r.

o r l o 0

- 0 0 1 m . . . .

m m m m k 7 r . r . W

0 0 0 0 . .

d m w d

0 0 0 0

w m c a m . . .

0 P- m 12 m h w . . 0 0 d l d

q 0 0

. . 0 0 d l d

m C 0 d m m d

m

al U m rl a 0 d U Y m a

a

; d U d M 1 w

m m 1 rl 0 C .A

U 0 E: 0 Q

m al a rl m > al m al L: w *

~~

I4 1 0 c \ m al L: m 7 a rn

* n

al

.A

.” m c 0 d U m N m a 0

d m 0 d a x U

al

5 m m

m aJ U m Y

U

m

.”, ; +I

m m al 0 0 U a Q 0 m m al U m U

0 0 d UI

d

W a

4.

U

: VI 0

C 0 U

I4 m a

m .d

al Y 0 0

W 0

e 0 U

m rc

0

U m c U

Q m U m 0 d Q e d

m m c C 0 .A U m U 0 a U 0 U

4 . 0 - 0 a l a U M

m m u L: a l r l d m e o u u al m x

a s

n m > U c - m U

0 U

d m U C

i! C 0 U d ? C W

c 0 U x m d U

.

5 . 1 . 5 P a r t i c u l a t e E m i s s i o n s f o r P u s h i n g O p e r a t i o n s

U s i n g t h e p a r t i c u l a t e e m i s s i o n s d a t a p r e s e n t e d

p r e v i o u s l y , t o g e t h e r w i t h a s t r a i g h t f o r w a r d c a l c u l a t i o n a l

- 5 9 -

e m i s s i o n s w e r e b e i n g e v a c u a t e d f r o m t h e s h e d . T h i s

3 - m i n u t e s a m p l i n g p e r i o d w a s d e t e r m i n e d e m p i r i c a l l y by

t h e m e t h o d o l o g y d i s c u s s e d i n S e c t i o n 4 . 4 . ,It should-be

n o t e d t h a t b e c a u s e o f t h e s a m p l i n g t e c h n i q u e , t%

e m i s s i o n r a t e s and f e e d r a t e s p resen t . ed i n T a b l e 5.1.4

h a v e b e e n a d j u s t e d t o a s sume t y p i c a l o p e r a t i o n s ' i . e . ,

4.5 p u s h e s p e r h o u r . The r e s u l t i n g e m i s s i o n f a c t o r s

f o r f i l t e r a b l e and t o t a l p a r t i c u l a t e a v e r a g e 0 . 6 4 and

0 . 6 9 pound o f p a r t i c u l a t e p e r t o n o f d r y c o a l f e d , o r

0.81 and 0.87 pound o f p a r t i c u l a t e p e r t o n of c o k e p r o -

d u c e d , r e s p e c t i v e l y .

/-- - - _ .

-'%

In a d d i t i o n t o p u s h i n g e m i s s i o n s , e m i s s i o n s f r o m

d o o r l e a k s , q u e n c h c a r movement , a n d r e s i d u a l c o n c e n t r a -

t i o n s f rom p r e v i o u s p u s h e s w e r e a l s o o b s e r v e d t o b e

e x h a u s t e d d u r i n g t h e 3 - m i n u t e "peak" p e r i o d s . T h u s , t h e

p e a k p a r t i c u l a t e e m i s s i o n s d a t a p r e s e n t e d in T a b l e 5 .1 .4

s h o u l d n o t b e c o n s i d e r e d a n e s t i m a t e o f t h e p a r t i c u l a t e

e m i s s i o n s f r o m c o k e p u s h i n g , p e r s e . T h e s e a d d i t i o n a l ,

v a r i a b l e s o u r c e s o f p a r t i c u l a t e e m i s s i o n s ( d o o r s a n d

q u e n c h c a r ) l i k e l y a c c o u n t f o r t h e w i d e r r a n g e o f d a t a

r e p o r t e d f o r t h e peak p a r t i c u l a t e e m i s s i o n s f rom t h e

e x h a u s t d u c t a s compared t o t h e r e s u l t s o f c o n t i n u o u s

s a m p l i n g . A more c o m p l e t e summary o f s a m p l i n g t i m e s ,

s ampled v o l u m e s , c o n c e n t r a t i o n s , a n d e m i s s i o n r a t e s c a n

b e found i n A p p e n d i x S S (Volume 6 ) .

I

- 6 0 -

procedure, it is possible to estimate the particulate emis-

sions due to pushing operations alone at Battery No. 1. By

assuming that the aggregate door leak emission rate within

the shed is essentially equivalent during pushing periods and

non-pushing periods, the emission rate due t o door leaks can _1

be estimated algebraically by consideration of emission rate - measurements from the two particulate sampling modes.

Referring to Figure 5.1.5, the total shaded area Bi

(diagonal lines upward and to the right) includes a single

push and the time following that push and preceding the next

push, and represents the mass of emissions occurring during

the continuous particulate sampling period tci, consisting of

door leaks, residuals of old pushes, and push emissions occur-

Area Ai (diagonal lines upward and to the ring during t

left) represents the mass of push emissions, residual emis-

sions, and door leaks measured during the peak particulate

sampling period, tpi. The time period t represents the

time required to evacuate the shed of most of the "current

push emissions."

the rectangular area that represents the mass of emissions due

Ci'

Pi

The difference of the two areas, B i - Ai, 'is

only to door leaks and residual concentrations from previous

pushes. A time-weighted fraction of this rectangle, (Bi-Ai)*

tpi/(tci- tpi), represents the "baseline" rectangular area's

contribution to the total peak emissions, Ai. Subtraction

then gives an estimate of the mass emissions ascribed only to

pushing:

tci - tpi Push-Only Mass Emissions = Ai - (Bi - Ai)

$ k .i

rn W

-

4 0

U w I1

al B 4 H

M a 4 d

2 a rn

-

W 1 0

C rl U a 0 V

a

-

4 , 0

U

4 0 W 1 &I

U a al u u V

d

I

a

a 1 -a 4 W al d

0 a H

n W U e U rl 1 W a 0 u d

a

a

.. W a

‘ X a W V 0

W

- 6 2 -

The c a l c u l a t i o n a l p r o c e d u r e d e s c r i b e d above i s shown

i n T a b l e 5.1.5. S i n c e a l l s a m p l e s were t a k e n on a m u l t i - p u s h

b a s i s , measu red e m i s s i o n s were n o r m a l i z e d t o a "per -push ' '

b a s i s by d i v i d i n g by t h e number o f p u s h e s i n c l u d e d i n e a c h

sample . Then, u s i n g t h e s a m p l i n g t i m e p e r push and t h e e q u a -

t i o n a b o v e , t h e p u s h i n g o p e r a t i o n s e m i s s i o n s c a p t u r e d by t h e

s h e d were e s t i m a t e d .

F u g i t i v e e m i s s i o n s wh ich e s c a p e d c a p t u r e by t h e shed

were e s t i m a t e d , a s d i s c u s s e d i n S e c t i o n 5.1.2, to b e 15 p e r -

c e n t (on a c o n t i n u o u s b a s i s ) o f t h e e m i s s i o n s c a p t u r e d by t h e

s h e d . Thus , i n o r d e r t o d e t e r m i n e t o t a l push e m i s s i o n s , t h e

e m i s s i o n s c a p t u r e d by t h e s h e d must be a d j u s t e d upward by d i -

r e c t r a t i o u s i n g t h i s f a c t o r . Us ing t h e p r o c e s s w e i g h t r a t e s ,

t h e o v e r a l l f i l t e r a b l e p a r t i c u l a t e e m i s s i o n f a c t o r s f o r t h e

p u s h i n g o p e r a t i o n s can a l s o be c a l c u l a t e d . These v a l u e s were

found t o r a n g e f r o m 0.48 t o 0.89, and a v e r a g e 0.69 pound p e r

t o n o f d r y c o a l f e d t o t h e o v e n s , o r 0.87 pound p e r t o n o f

._._- .. ._.. 2 ---... ----___.

5.1.6 P a r t i c u l a t e E m i s s i o n s f o r Non-Pushing O p e r a t i o n s

Us ing t h e e v a l u a t i o n s p r e s e n t e d i n S e c t i o n s 5.1.3 and

5.1.5, t h e e m i s s i o n s f rom non-push ing o p e r a t i o n s a r e c a l c u -

l a t e d by d i f f e r e n c e , a s shown i n T a b l e 5.1.6. These e m i s s i o n

f a c t o r s i n c l u d e d o o r l e a k s , r e s i d u a l s f rom p a s t p u s h e s , and

e m i s s i o n s f rom quench c a r movement. They h a v e b e e n c o r r e c t e d

f o r f u g i t i v e e m i s s i o n s and t h u s p r o v i d e a n e s t i m a t e o f t h e

o v e r a l l c o k e - s i d e e m i s s i o n s f o r n o n - p u s h i n g o p e r a t i o n s . The

v a l u e s r a n g e f rom 0.04 t o 0 .41, and a v e r a g e 0.22 pound o f

f i l t e r a b l e p a r t i c u l a t e p e r t o n o f d r y c o a l , o r 0.3 pound p e r

\

. r l u m

0 0 c \ u m a 0 3

7 0 a e

n o . u .j

U m a l

7 0

2 w

. n m ..CI

d m V ." 7

m m e o o u U m m I J d m o s

0 r l o m o w d o h e u o

U al E m 7 - m . m o m

U m a m e u u m U P

m U U

M U d r l 0 - 3 3 c

d

m m a m o s 0 u c a 0

d m u c m m u

0

m u u o m u IJ e m o m r l u m v l

d n

n w

n

m

m n

3

- 63 - 4 0 1 o d m . . . 030

m m r l d m - . . . 0 0 0

0 e H

n Io U c m U d 7 m c 0 0

rl m U e m

2 0

d > 0 W

0 0 U h m rl 0

m y l m FINN r l3d

. . . v.,

c

m - m . . . *Y)Y) N N N

m m m . . . W e 0 3"

z 0 H vl m H

W E

L & u

m m m N N N

m b p 1 l n m n 3rlrl

N

o o m rlrl

- m o

m m m m m m N N N

000 W W W

m m r l N N N drlrl

r lN rn 3 N m

m W Y ) . . . m * m F IN3

m 7 0 7 e d 4J e 0 U

m u fLw m h0 0) u u

m

W

4

In

W cl F9 -=2 H

G 0

c $ 0

2;;". n u 4

m d m . . . 0 0 0

4 0

0 4 0

w d m

m m d * c o b

0 0 0 . . .

4"

4 4 4 . .

m m w m m m . . . 0 0 0

0 G H

4 m

rl ? e W

- 65 -

t o n o f coke p r o d u c e d . T h i s t a b l e t h u s i n d i c a t e s t h a t t h e

p u s h i n g o p e r a t i o n s a c c o u n t f o r 76 p e r c e n t o f t h e o v e r a l l

e m i s s i o n s , w h i l e t h e n o n - p u s h i n g o p e r a t i o n s a c c o u n t f o r

2 4 p e r c e n t .

5 .2 P a r t i c u l a t e C a p t u r e E f f i c i e n c y o f t h e Shed

5.2.1 E v a l u a t i o n o f Shed C s p t u r e E f f i c i e n c y

The a v e r a g e e m i s s i o n f a c t o r f o r c o n t i n u o u s f i l t e r a b l e

p a r t i c u l s t e e m i s s i o n s f rom t h e e x h a u s t d u c t was 0 . 7 8 pound

p e r t o n o f d r y c o a l f e d t o t h e o v e n s , a s shown i n T a b l e

5 .1 .1 . Us ing t h e a v e r a g e f u g i t i v e e m i s s i o n f a c t o r d e v e l o p e d

i n S e c t i o n 5.1.2, 0'.14 pound p e r t o n o f d r y c o a l , t h e p a r -

t i c u l a t e c a p t u r e e f f i c i e n c y o f t h e s h e d may be c a l c u l a t e d

a s f o l l o w s :

E - 0.14/(0.14 + 0 . 7 8 g X 100 = 85%.

T h u s , on s c o n t i n u o u s b a s i s , a n a v e r a g e o f 8 5 p e r c e n t o f t h e

f i l t e r a b l e p a r t i c u l a t e e m i s s i o n s a r e c a p t u r e d by t h e s h e d .

5.2.2 P o s s i b l e C a u s e s o f Leakage

The f o l l o w i n g a r e p o s s i b l e r e a s o n s f o r t h e s h e d ' s

f u g i t i v e p a r t i c u l a t e e m i s s i o n s :

1. The o v e r a l l s i z e o f t h e s h e d ' s h o l d i n g chamber

( s e e F i g u r e s 3.1-2 and 3.1-3) a p p e a r e d t o b e

t o o s m a l l r e l a t i v e t o t h e m a g n i t u d e o f t h e emis-

s i o n s and t h e e f f e c t i v e e v a c u a t i o n r a t e of t h e

s h e d . T h i s was s u b s t a n t i a t e d by t h e e x h a u s t

d u c t o p a c i t y o b s e r v a t i o n s , w h i c h documented t h a t

t h e s h e d was n o t c o m p l e t e l y c l e a r e d o f p u s h

- 6 6 -

e m i s s i o n s i n 2 t o 3 m i n u t e s ( a s d e s i g n e d , p e r

M r . R o b e r t Harvey o f Be th lehem S t e e l C o r p o r a t i o n ) .

I n s t e a d i t a p p e a r e d t h a t c l e a r i n g o f t h e p u s h

( p e a k ) e m i s s i o n s s o m e t i m e s t o o k l o n g e r t h a n 10

m i n u t e s ( p e r h a p s 14 t o 15 m i n u t e s ) . T h i s i s

i m p o r t a n t f o r two r e a s o n s :

a . The s h e d ' s h o l d i n g and e v a c u a t i o n c a p a c i t i e s

may have b e e n e x c e e d e d i n t h e many (32 p e r -

c e n t ) i n s t a n c e s when t h e t i m e be tween p u s h e s

w a s o n l y 8 t o 9 m i n u t e s ; i . e . , be low t h e

" a v e r a g e " c y c l e d u r a t i o n o f 13 m i n u t e s .

T h i s meant a n 8- t o 9 -minu te p u s h - t o - p u s h

i n t e r v a l was s l i g h t l y be low t h e " o b s e r v e d "

p e r i o d r e q u i r e d f o r p u s h e m i s s i o n s c l e a r i n g .

Shed l e a k a g e was l i k e l y a l s o i n c r e a s e d by t h e

( n o t i n f r e q u e n t ) o c c u r r e n c e of h i g h l y emis-

s i v e ( " g r e e n " ) coke-oven p u s h e s . When t h e

s h e d ' s c a p a c i t i e s were e x c e e d e d , t h e p a r t i c u -

l a t e e m i s s i o n s " o v e r f l o w e d " from a n y o p e n i n g s

b e l o w t h e s h e d ' s h o l d i n g chamber . I n t h i s

e v e n t , some of t h e p a r t i c u l a t e m a t e r i a l sus-

pended i n t h e s h e d ' s h o l d i n g chamber l i k e l y

moved beyond t h e " c a p t u r e " r a n g e o f t h e ex -

h a u s t d u c t and i n t o t h e r e g i o n where wind

e f f e c t s were more p r o n o u n c e d . The p r o b a b l e

r e s u l t of t h i s " u n d e r s i z i n g " was l e a k a g e

f rom any shed o p e n i n g s s u c h a s t h o s e l o c a t e d

a t b o t h e n d s o f t h e s h e d and t o p s i d e .

1

-.

7

- 6 7 -

b. The h o t , p a r t i c u l a t e - l a d e n g a s e s may h a v e

a l s o d r o p p e d beyond t h e r e a c h o f t h e e x h a u s t

d u c t b e c a u s e o f c o o l i n g c a u s e d by t h e a t t e m p t

t o h o l d t h e e m i s s i o n s i n t h e h o l d i n g chamber

beyond t h e d e s i g n d u r a t i o n .

2 . A s i m p l i e d i n t h e f i r s t i t e m , p e r h a p s t h e s h e d

e x h a u s t r a t e was t o o low. D u r i n g t h e t e s t p e r i o d ,

e x h a u s t g a s f l o w r a t e m e a s u r e m e n t s i n d i c a t e d t h a t

a i r f l o w was a b o u t 10 p e r c e n t be low t h e r a t e i d e n t i -

f i e d by t h e f a c i l i t y t o b e i t s optimum r a t e on t h e

b a s i s of e m i s s i o n c l e a r i n g t i m e . However, a s s u r -

a n c e s were g i v e n by B e t h l e h e m S t e e l C o r p o r a t i o n

t h a t t h e e x h a u s t r a t e was a t maximum c o n d i t i o n s

a n d , s i n c e t h e s t a c k g a s e x h a u s t r a t e was w i t h i n t h e

+ 1 0 p e r c e n t c r i t e r i o n d i s c u s s e d i n S e c t i o n 3 . 2 . 1 ,

s a m p l i n g commenced.

-

3. I t is p o s s i b l e t h a t " s h o r t c i r c u i t i n g " o f t h e

o u t s i d e a i r (wh ich e n t e r s t h e s h e d t h r o u g h i t s

e n d s and o p e n s i d e ) t o t h e e x h a u s t d u c t o c c u r r e d

d u e t o t h e : ( 1 ) m a g n i t u d e o f t h e o p e n i n g s ,

p a r t i c u l a r l y a t t h e e n d s o f t h e s h e d ; a n d ( 2 )

t h e v a r y i n g c r o s s - s e c t i o n a l a r e a o f t h e o p e n i n g s .

If t h i s h a p p e n e d , t h e " a c t u a l " e m i s s i o n e x h a u s t

r a t e would b e r e d u c e d . T h i s phenomenon c o u l d

h a v e f u r t h e r r e d u c e d t h e s h e d ' s p e r f o r m a n c e

b e c a u s e t h e r e s u l t i n g i n l e t a i r f l o w p a t t e r n would

d i s t u r b , r a t h e r t h a n e n h a n c e , t h e d e s i r e d p a t t e r n

o f a i r f l o w i n t h e s h e d .

- 6 8 -

4 . The c a p t u r e p r o b l e m may have b e e n c a u s e d , a t

l e a s t i n p a r t , by t h e h o l d i n g c h a m b e r , i t s i n l e t ,

a n d / o r t h e e x h a u s t d u c t .

a . The s h a p e o f t h e s h e d ' s h o l d i n g chamber , i n

c o n j u n c t i o n w i t h t h e s i z e o f i t s i n l e t

( " t h r o a t " ) m i g h t h a v e a f f e c t e d t h e s h e d ' s

i n i t i a l e m i s s i o n c a p t u r e e f f i c i e n c y a n d s u b -

s e q u e n t h o l d i n g c a p a c i t y .

b . The s h a p e , s i z e , a n d l o c a t i o n of t h e e x h a u s t

d u c t ( l o c a t e d a t t h e t o p of t h e h o l d i n g

chamber) may h a v e s i g n i f i c a n t l y a f f e c t e d t h e

r a t e and e f f i c i e n c y o f i t s e m i s s i o n e x h a u s t .

.

5 . The s h e d w a l l a n d end o p e n i n g s may h a v e f u r t h e r

a f f e c t e d t h e p e r f o r m a n c e i n t h r e e ways:

a . Such o p e n i n g s p r o v i d e d p o t e n t i a l e s c a p e r o u t e s

f o r f u g i t i v e e m i s s i o n s .

,b. nc i e a s r : some or c n e o p e n i n g s a p p e a r e a K O

a l l o w t h e w i n d t o i n t e r a c t w i t h t h e e m i s s i o n s

w i t h i n t h e s h e d . S e v e r a l i n s t a n c e s were ob- - s e r v e d when t h e wind

d i r e c t l y o u t t h e end

were c a p t u r e d .

C . The r e l a t i v e l y l a r g e

b l e w c o k e - s i d e d o o r l e a k s

of t h e s h e d , b e f o r e t h e y

end o p e n i n g s may n o t

h a v e p e r m i t t e d optimum u s e o f t h e i n l e t a i r .

I d e a l l y , t h e a i r s h o u l d have e n t e r e d t h e

s h e d u n i f o r m l y , a n d p r e f e r a b l y o n l y a l o n g

i t s open s i d e . T h i s would h a v e enhanced t h e

- 69 -

.

e n t r a i n m e n t o f t h e p a r t i c u l a t e e m i s s i o n s by

r e i n f o r c i n g t h e s p i r a l a i r p a t t e r n b e i n g

e s t a b l i s h e d i n t h e s h e d by t h e combined e f f e c t

o f t h e r i s i n g h o t e m i s s i o n g a s e s and t h e s h a p e

of t h e s h e d h o l d i n g c h s m b e r .

5.3 C h e m i c a l C o m p o s i t i o n o f P a r t i c u l a t e E m i s s i o n s

N i n e t e e n s e p a r a t e a n a l y s e s o f t h e p a r t i c u l a t e s a m p l e s ( b o t h con-

t i n u o u s and p e a k ) w e r e p e r f o r m e d . T a b l e 5.3-1 p r e s e n t s t h e r e s u l t s

o f t h e a n a l y s e s f o r s u l f a t e and 10 m e t a l i o n s i n t e r m s o f p e r c e n t o f

b o t h f i l t e r a b l e a n d t o t a l p a r t i c u l a t e w e i g h t . The c o n t r i b u t i o n o f

t h e s e s u b s t a n c e s t o t h e p a r t i c u l a t e e m i s s i o n s was q u i t e s m a l l . The

o n l y s u b s t a n c e found i n a n amount g r e a t e r t h a n o n e p e r c e n t was sul-

f a t e (2.3 t o 4.5 p e r c e n t ) . T h u s , c a r b o n a c e o u s m a t e r i a l ( c o k e ) con-

s t i t u t e d t h e m a j o r i t y o f t h e p a r t i c u l a t e m a t t e r c a p t u r e d .

T a b l e 5.3-2 p r e s e n t s t h e a v e r a g e e m i s s i o n r a t e s f o r t h e s e 11

s u b s t a n c e s a s w e l l a s t h e a v e r a g e e m i s s i o n s o f a c e t o n e - s o l u b l e p a r -

t i c u l a t e , w a t e r - s o l u b l e p a r t i c u l a t e , a n d o t h e r w a t e r - s o l u b l e

s u b s t a n c e s . Note t h a t i n t h i s t a b l e e m i s s i o n r a t e s f o r p e a k s a m p l e s

h a v e b e e n a d j u s t e d t o a n a v e r a g e p u s h i n g r a t e o f 4.5 p u s h e s p e r h o u r .

The a c e t o n e - s o l u b l e c o n t e n t o f t h e f i l t e r a b l e c o n t i n u o u s and p e a k

e m i s s i o n s a v e r a g e d 13 a n d 12 p e r c e n t , r e s p e c t i v e l y . The w a t e r -

s o l u b l e c o n t e n t a v e r a g e d two p e r c e n t f o r b o t h t y p e s o f s a m p l e s .

T a b l e 5.3-3 p r e s e n t s t h e pH and a c i d i t y o f t h e f r o n t and back-

h a l f c a t c h e s o f e a c h o f t h e p a r t i c u l a t e s a m p l e s . A l t h o u g h t h e

v a l u e s v a r y , a l l f r a c t i o n s w e r e found t o b e a c i d i c .

5.4 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 r e s u l t s o f t h e f o u r p a r t i c l e s i z e s a m p l e s a r e p l o t t e d i n

F i g u r e 5.4. The l i n e s a r e l a b e l e d a c c o r d i n g t o t h e p o i n t w i t h i n

- 7 0 -

v) w cl & E: -4 v)

W U

3 0 H F! e: 4

3

d r + I O

m * F !

w H

cl 3 v1

2

n z 4

c 0 4

Y al m

..

U 0 . a l o w z

m e e d m 3 0 0 0 00

00 0 0 00 . . . . . .

m N N O N N N 00 0 0 00 00 0 0 00

00 0 0 00 . . . . . . .

v v v v \ D m \DI. w r . 00 0 0 00 00 0 0 00 00 0 0 00

00 0 0 00 . . . . . .

v v v v v v

N N N N N N 00 0 0 00 00 0 0

00 00 0 0

e* N N -4.3 00 0 0 00 00 0 0 00 00 0 0 00

. . . . . .

. . . . . . 00 0 0 00

\D\D N N \ D m 00 0 0 0 0 . . . . . .

e 4 . o w 44 0 0 0 0 00 0 0 00 . . . . . . 00 0 0 0 0

r . m 34 0 0 43 00 0 0 00

00 0 0 00 . . . . . .

m m m m m m . . . . . . 00 00 00

r ( N m e N m 00 00 00

00 00 00 . . . . . .

0 3 u.4 u.4 c a c m c a o u o u o u $40 N O N O Fru h U r4u

rl N m

m

0

c +( U c 0 U

a a

d e m m vlr.

m * N N N N . . . . . . e e \DID m e 0 0 00 00

0 0 00 00 . . . . . .

m e N m Ne 0 0 00 00 0 0 00 00

0 0 00 0 0 v v v v v P I C 0 m m

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0 0 00 00 0 0 00 00

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I .

TABLE 5 . 3 - 3

SUMMARY OF WATER SOLUBLE pH A N D A C I D I T Y I A L K A L I N I T Y OF PARTICULATE SAMPLES

B u r n s H a r b o r P l a n t

Che s t e r t o n , I n d i a n a B e t h l e h e m S t e e l C o r p o r a t i o n

March 3 - 7 , 1 9 7 5

S a m p l i n g C o n d i t i o n s

C o n t i n u o u s

P u s h e s Only

T e s t No.

' 1 ' 1

2 2

3 3

P o r t i o n o f

S a m p l i n g T r a i n

F r o n t Back

F r o n t Back

F r o n t Back

F r o n t Back

F r o n t Back

F r o n t Back

P H

3 . 0 4 . 9

6 . 6 4 . 2

3 . 1 3 . 8

5.8 4 . 5

4 . 4 4 . 3

2 . 9 4 . 3

A c i d i t y *

2 . 2 0 .6

< 0 . 3 0 . 2

1 . 3 0 . 3

< 0 . 3 0 . 4

0 . 2 0 . 5

0 . 6 0 . 4

* T o t a l m i l l i e q u i v a l e n t s of NaOH a d d e d t o a t t a i n a pH o f 7 . 0

C l a y t o n E n v i r o n m e n t a l C o n s u l t a n t s , I n c .

~~~ ~-

- 74 - 0

H

, . - 7 5 -

.i

(C

t h e e x h a u s t d u c t a t - w h i c h t h e s a m p l e was o b t a i n e 4 shown p r e v i o u s l y

i n F i g u r e 4 . 2 - 3 . The w e i g h t s f o r e a c h s t a g e and t h e i n d i v i d u a l

d i s t r i b u t i o n s a r e p r e s e n t e d i n A p p e n d i x T T (Volume 6). T h e s e

d a t a show t h a t t h e p a r t i c l e s i z e d i s t r i b u t i o n v a r i e s somewhat

a c r o s s t h e d u c t , p r o b a b l y d u e t o t h e c h a n g e s i n d i r e c t i o n o f t h e

e x h a u s t g a s f l o w w i t h i n t h e d u c t . However , a s t a t i s t i c a l c o m p a r i -

s o n ( c h i - s q u a r e t e s t f o r i n d e p e n d e n c e ) o f t h e p e r c e n t a g e o f p a r t i -

c u l a t e l e s s t h a n o n e m i c r o n a n d t h e p e r c e n t a g e l e s s t h a n f i v e

m i c r o n s shows n o s t a t i s t i c a l l y s i g n i f i c a n t d i f f e r e n c e among t h e

f o u r p a r t i c l e s i z e d i s t r i b u t i o n s .

The d a t a i n F i g u r e 5 . 4 i n d i c a t e t h a t b e t w e e n 1 2 a n d 62 p e r c e n t - - (by w e i g h t ) o f t h e f i l t e r a b l e p a r t i c u l a t e was s m a l l e r t h a n s e v e n

m i c r o n s ( a e r o d y n a m i c d i a m e t e r ) . F u r t h e r , b e t w e e n f o u r a n d 1 7

p e r c e n t o f t h e f i l t e r a b l e p a r t i c u l a t e was s m a l l e r t h a n one m i c r o n

( a e r o d y n a m i c d i a m e t e r ) . The a v e r a g e s t a c k - g a s p a r t i c l e - s i z e

d i s t r i b u t i o n c a n b e e s t i m a t e d by a v e r a g i n g t h e d i s t r i b u t i o n s i n

F i g u r e 5 . 4 . Based on t h i s p r o c e d u r e , a b o u t 3 2 p e r c e n t o f t h e

f i l t e r a b l e p a r t i c u l a t e was s m a l l e r t h a n s e v e n m i c r o n s , a n d a b o u t

seven p e r c e n t was s m a l l e r t h a n one m i c r o n .

The c o n c e n t r a t i o n o f f i l t e r a b l e p a r t i c u l a t e m a t t e r was a l s o . c a l c u l a t e d f o r e a c h o f t h e p a r t i c l e s i z e s a m p l e s . The r e s u l t s ,

d i s p l a y e d i n T a b l e 5 . 4 , i n d i c a t e a r a n g e f r o m 0 . 1 0 5 t o 0 . 2 6 0 gr/DSCF.

S i n c e t h e s a m p l i n g p e r i o d f o r e a c h of t h e s e t e s t s i n c l u d e d a s i n g l e

push and r a n g e d f r o m e i g h t t o 1 2 m i n u t e s , t h e s e c o n c e n t r a t i o n s

s h o u l d f a l l (on a n a v e r a g e b a s i s ) b e t w e e n t h o s e o b t a i n e d d u r i n g

c o n t i n u o u s and p e a k p a r t i c u l a t e s a m p l i n g , w h i c h t h e y d o . T h u s ,

t h e s e r e s u l t s compare f a v o r a b l y w i t h t h o s e o b t a i n e d d u r i n g t h e

p a r t i c u l a t e t e s t s .

- 76 -

Sampling Point Numb e r

P- 1

P- 2

P- 3

P- 4

TABLE 5.4

PARTICULATE CONCENTRATION AND ACETONE-SOLUBLE CONTENT OF PARTICLE SIZE SAMPLES

Burns Harbor Plant Bethlehem Steel Corporation

Chesterton, Indiana March 3-7, 1975

Samp 1 in g Particulate Percent Concentration Acetone 1975 Period

Date (gr/DSCF) Solubles

3-6 09:05 0 9 ~ 1 3 0.260 48

3-6 18:26 18:38 0.142 6 3

3-7 08:27 08:35 0.105 13

3-6 12:59 1 3 ~ 0 7 0.147 34

Start Stop

Clayton Environmental Consultants, Inc.

- 7 7 -

2% . ./

.i

, .,

T a b l e 5.4 a l s o i n d i c a t e s t h e a c e t o n e - s o l u b l e c o n t e n t f o r e a c h

o f t h e s a m p l e s . T h e s e v a l u e s v a r y g r e a t l y , r a n g i n g f rom 13 t o 6 3

p e r c e n t . I n a d d i t i o n , t h e a c e t o n e - s o l u b l e c o n t e n t was d e t e r m i n e d

f o r t h r e e f r a c t i o n s o f e a c h t e s t : t h e p a r t i c u l a t e m a t t e r c o l l e c t e d

i n t h e c y c l o n e , t h a t c o l l e c t e d on t h e f i v e s t a g e s o f t h e i m p a c t o r ,

and t h a t c o l l e c t e d on t h e back-up f i l t e r . T h i s breakdown o f t h e

a c e t o n e - s o l u b l e c o n t e n t b y s i z e r a n g e s i s g i v e n i n t h e t a b l e s

i n c l u d e d i n Append ix T T (Volume 6 ) . A s t a t i s t i c a l t e s t (one-way

a n a l y s i s o f v a r i a n c e ) i n d i c a t e s t h a t t h e r e i s no s t a t i s t i c a l l y

s i g n i f i c a n t d i f f e r e n c e b e t w e e n t h e mean a c e t o n e - s o l u b l e c o n t e n t

o f t h e s e v a r i o u s s i q e r a n g e s . -

, 5.5 E m i s s i o n s of O t h e r M a t e r i a l s

T a b l e 5 . 5 p r e s e n t s t h e a v e r a g e e m i s s i o n s f o r a l l c o n t a m i n a n t s

o t h e r t h a n p a r t i c u l a t e m a t t e r . The f o l l o w i n g s u b s t a n c e s were

measu red a t l e v e l s e x c e e d i n g 1 0 0 pounds p e r h o u r : c y c l o h e x a n e

i n s o l u b l e s ( 2 0 3 l b s / h r ) , c y c l o h e x a n e s o l u b l e s ( 2 9 1 l b s / h r ) , e t h y l e n e

a n d homologues (147 l b s / h r ) , and t o t a l l i g h t h y d r o c a r b o n s ( 1 3 1

l b s / h r ) . O t h e r c o n t a m i n a n t s were d e t e c t e d a t l e v e l s t h a t a v e r a g e d

l e s s t h a n 1 6 pounds p e r h o u r : a c e t y l e n e , ammonia, b e n z e n e , ben-

zene homologues , b e n z o ( a + e ) p y r e n e , p - n a p h t y l a m i n e , c a r b o n monox ide ,

s o l u b l e c h l o r i d e , c h r y s e n e p l u s t r i p h e n y l e n e p l u s 1 , 2 - b e n z a n t h r a c e n e ,

complex s o l u b l e c y a n i d e , i n s o l u b l e c y a n i d e , s i m p l e s o l u b l e c y a n i d e ,

f l u o r h t h e n e , h y d r o g e n s u l f i d e , m e t h a n e and homologues , n i t r a t e

p l u s n i t r i t e , t o t a l i n s o l u b l e p h e n o l i c s , t o t a l s o l u b l e p h e n o l i c s ,

-f-

r

,+-

, '

,' A p y r e n e , p y r i d i n e , i n s o l u b l e s u l f a t e , t o t a l s u l f a t e , t o t a l s u l f i t e ,

s u l f u r d i o x i d e , and s u l f u r i c a c i d m i s t . The sampled volumes and

s a m p l i n g c o n d i t i o n s , a s w e l l a s c o n c e n t r a t i o n s and e m i s s i o n r a t e s

f o r i n d i v i d u a l t e s t s , a r e p r e s e n t e d i n Append ix UU (Volume 6 ) .

- 7 8 - TABLE 5.5

SUMMARY OF AVERAGE EMISSION RATES OF "OTHER" EMISSIONS

Burns H a r b o r P l a n t Be th lehem S t e e l C o r p o r a t i o n

C h e s t e r t o n , I n d i a n a March 3 - 7 , 1 9 7 5

A c e t y l e n e Ammonia Benzene Benzene Homologues ( a s C6H6) B e n z o ( a + e ) P y r e n e B e t a - N a p h t h y l a m i n e Carbon Monoxide S o l u b l e C h l o r i d e C h r y s e n e + T r i p h e n y l e n e + 1 , 2 -

B e n z a n t h r a c e n e ( a s C h r y s e n e ) Complex S o l u b l e Cyan ide I n s o l u b l e C y a n i d e S i m p l e S o l u b l e C y a n i d e C y c l o h e x a n e I n s o l u b l e s C y c l o h e x a n e S o l u b l e s E t h y l e n e & Homologues ( a s C 2 H 4 ) F l u o r a n t h e n e T o t a l L i g h t H y d r o c a r b o n s ( a s CH4) Hydrogen S u l f i d e Methane & H o m o l o g u e s (as CH4)

T o t a l I n s o l u b l e P h e n o l i c s ( a s

T o t a l S o l u b l e P h e n o l i c s ( a s

P y r e n e P y r i d i n e I n s o l u b l e S u l f a t e T o t a l S u l f a t e T o t a l S u l f i t e S u l f u r D i o x i d e S u l f u r i c Ac id M i s t ( a s SO3)

X,II* . ."*^ I n,LI.1&-1.... I - - .rn=\ '-- - - J ' . - - - - - - _. - - - - - - C 6 H 5 0 H )

C6H50H)

A v e r a g e E m i s s i o n R a t e

l b s f h r

0 .4- 0 .5* 0 .34-0 .44

4 .1 <I .7

<O. 35 6 . 9 * 4.6

0.9-1.2

0 .8 -1 .3 0.03 0 . 0 1 0 .03 203 291 1 4 7 *

0 . 7 - 1 - 2 131 * 0.93 5 . 8 *

n * n n I n ".ad - " ._"

<O. 06

0.89 <0.86 <0.15 <0.13 15 .7

6 .2 1 2 . 6

2 . 2

k g s f h r

0.2*

1 . 9 <O. 77

< O . 1 6 3 . 2 * 2 . 1

0 .4-0 .6 0 . 0 1

0 .004-0 .005 0 .01 92 1 3 2 67 * 60 * 0 .42 2 . 7 "

0.16-0.20

0 . 4 - 0 . 5 .

0 .3-0 .6

n .- n .- ". .a_". A"

<O .03

0 . 4 0 <0.39 <0.07 <0.05

7 . 2 2 .8 5 .7 1 . 0

* E m i s s i o n s measu red d u r i n g peak p e r i o d s . These d a t a h a v e b e e n c o n v e r t e d t o t y p i c a l o p e r a t i o n s ; i . e . , 4.5 p u s h e s / h o u r . All o t h e r s a m p l e s were t a k e n on a c o n t i n u o u s b a s i s .

C l a y t o n E n v i r o n m e n t a l C o n s u l t a n t s , I n c .

- 7 9 -

i

..' ./

The sum o f t h e a v e r a g e c y c l o h e x a n e - s o l u b l e a n d c y c l o h e x a n e -

i n s o l u b l e e m i s s i o n s ( t e r m e d c a t e g o r y "1") s h o u l d be c o m p a r a b l e t o

t h e sum of t h e a v e r a g e e m i s s i o n r a t e s f o r t o t a l p a r t i c u l a t e and

o r g a n i c m i s t s and g a s e s ( t e r m e d c a t e g o r y " 2 " ) . T h i s i s t o be

e x p e c t e d b e c a u s e t h e s a m p l i n g and a n a l y t i c a l p r o c e d u r e s t e n d t o

i n d i c a t e t h a t t h e m a t e r i a l s c a p t u r e d , m e a s u r e d , and c l a s s i f i e d

by t h e two p r o c e d u r e s s h o u l d h a v e a p p r o x i m a t e l y t h e same a g g r e g a t e

v a l u e . A c o m p a r i s o n o f t h e s e two c a t e g o r i e s d o e s i n d i c a t e a p p r o x i -

m a t e l y t h e same e m i s s i o n r a t e ; c a t e g o r y " 2 " is . a b o u t 8 6 p e r c e n t

o f c a t e g o r y "1." T h u s , t h e two i n d i v i d u a l c o n t a m i n a n t c a t e g o r i e s

'' cy c 1 o he xa n e so 1 ub 1 e s " a n d I' cy c 1 oh e x a n e i n s o 1 ub 1 e s " s ho u 1 d be

c o n s i d e r e d a s i n g l e c a t e g o r y t o be compared w i t h t h e sum o f t h e

t o t a l p a r t i c u l a t e a n d o r g a n i c m a t e r i a l s e m i s s i o n s , and n o t a s

s e p a r a t e e m i s s i o n s .

It s h o u l d be n o t e d t h a t , i n t h e f i e l d , low a m b i e n t t e m p e r a t u r e s

c a u s e d f r e e z e - u p o f t h e ( s t a n d a r d ) i m p i n g e r s o l u t i o n c o n t a i n i n g

c y c l o h e x a n e ; m i d g e t i m p i n g e r s (where t e m p e r a t u r e c o u l d be c o n t r o l l e d )

were s u b s t i t u t e d , b u t s a m p l i n g r a t e s were be low i s o k i n e t i c con-

d i t i o n s . Because t h e a m b i e n t t e m p e r a t u r e p r e c l u d e d i s o k i n e t i c

s a m p l i n g f o r c y c l o h e x a n e s o l u b l e s , c y c l o h e x a n e i n s o l u b l e s , f l u o r a n -

t h e n e , p y r e n e , c h r y s e n e p l u s t r i p h e n y l e n e p l u s 1 , Z - b e n z a n t h r a c e n e ,

a n d b e n z o ( a + e ) p y r e n e , t h e r e p o r t e d r e s u l t s may b e somewhat h i g h

f o r t h e s e c o n t a m i n a n t s . I n r e t r o s p e c t , t h i s a l t e r a t i o n i n f i e l d

s a m p l i n g was f a v o r a b l e w i t h r e s p e c t t o t h e measu remen t o f f l u o r a n -

t h e n e , p y r e n e , c h r y s e n e p l u s t r i p h e n y l e n e p l u s 1 , Z - b e n z a n t h r a c e n e ,

a n d b e n z o ( a + e ) p y r e n e b e c a u s e t h e s e c o n t a m i n a n t s may o t h e r w i s e h a v e

b e e n found t o be be low l i m i t s o f a n a l y t i c a l d e t e c t i o n .

- 80 -

5.6 I n d i c e s o f V i s i b l e E m i s s i o n s

5.6.1 D e g r e e of Greenness

D u r i n g t h e d e s i g n o f t h e s t u d y , i t became n e c e s s a r y t o

d e v e l o p a s e m i - q u a n t i t a t i v e m e a s u r e m e n t s c a l e t o document t h e -

.. r e l a t i v e d e g r e e o f v i s i b l e p a r t i c u l a t e e m i s s i o n s g e n e r a t e d by

t h e c o k e o v e n s d u r i n g p u s h i n g . The method a n d measu remen t - s c a l e f o r m u l a t e d t o c h a r a c t e r i z e a n o b s e r v e r ' s e s t i m a t e o f

t h e e m i s s i o n s ( v i s i b l e o b s c u r a t i o n ) g e n e r a t e d f rom a s i n g l e

coke -oven p u s h ( c o k e f a l l a n d q u e n c h c a r movement) i n c o r p o r a t e s

t h e t e r m " d e g r e e o f g r e e n n e s s , " a t e r m u s e d w i d e l y i n t h e s t e e l

i n d u s t r y a s a s u b j e c t i v e a s s e s s m e n t o f t h e a p p e a r a n c e o f visi-

b l e e m i s s i o n s g e n e r a t e d f r o m coke -oven p u s h i n g .

S p e c i f i c a p p l i c a t i o n s o f t h i s i n d e x a r e d e m o n s t r a t e d

in T a b l e s 5 . 6 . 1 - 1 t h r o u g h 5 . 6 . 1 - 6 , w h i c h p r e s e n t t h e d e g r e e -

o f - g r e e n n e s s r a t i n g s , t h e sum o f t h e r a t i n g s , and t h e p r o d u c t

o f t h e sum o f t h e r a t i n g s a n d t h e d u r a t i o n of t h e p u s h f o r

e a c h i n d i v i d u a l push d u r i n g b o t h t h e c o n t i n u o u s and p e a k

p a r t i c u l a t e s a m p l e s .

r a t i n g s and t h e d u r a t i o n o f t h e p u s h f o r t h e six t e s t s r a n g e d

f rom 222 f o r Peak P a r t i c u l a t e T e s t No. 1 t o 285 f o r P e a k

P a r t i c u l a t e T e s t No. 3 . T h u s , t h e t h i r d s a m p l i n g p e r i o d con-

t a i n e d p u s h e s o f h i g h e r g r e e n n e s s r a t i n g s t h a n d i d t h e o t h e r

The a v e r a g e p r o d u c t o f t h e sum o f t h e

two s a m p l i n g p e r i o d s .

T a b l e 5.6.1-7 p r e s e n t s t h e d e g r e e - o f - g r e e n n e s s d a t a

f o r t h e p a r t i c l e s i z e s a m p l e s , e a c h o f w h i c h was c o n d u c t e d

d u r i n g a s i n g l e p u s h . The t h r e e s a m p l e s f o r wh ich g r e e n n e s s

d a t a w e r e o b t a i n e d had r e l a t i v e l y h i g h v a l u e s , r a n g i n g f rom

- 81 -

In V H €4 m H

-

m m w E 0 w al t4 c)

U 0

w w $4 M w a

-

P c w a s > m 0 1

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m m m m o o o o o m o o o o l l l w m w l m m r f l r f w m N r f m m r f l l l 1

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- 8 8 -

280 t o 3 0 8 . The f i e l d d a t a s h e e t s f o r t h e s e g r e e n n e s s

r a t i n g s , a s w e l l a s t h o s e f r o m t h e p a r t i c u l a t e s a m p l e s , a r e

p r e s e n t e d i n A p p e n d i x V V (Volume6) .

5.6.2 O p a c i t y

5.6.2.1 E m i s s i o n s f r o m E x h a u s t Duct

A l t h o u g h F i g u r e 3 . 1 - 2 s c h e m a t i c a l l y shows

t h e s h e d e x h a u s t d u c t w i t h one e x i t s t a c k , i n f a c t ,

two s t a c k s w e r e u s e d t o d i s c h a r g e t h e e m i s s i o n s f r o m

t h e s h e d e x h a u s t d u c t d u r i n g t h e s t u d y . F u r t h e r , a

t h i r d e x h a u s t s t a c k was s e a l e d c o m p l e t e l y d u r i n g t h i s

s t u d y . The o p a c i t y d a t a a c q u i r e d f o r t h e two s t a c k s

were a v e r a g e d and t h e r e a f t e r t r e a t e d m a t h e m a t i c a l l y a s

i f t h e r e were o n l y a s i n g l e s t a c k . T h e s e s v e r a g e opa-

c i t y d a t a f o r t h e 3 - m i n u t e peak p e r i o d s d u r i n g t h e

p a r t i c u l a t e s a m p l i n g , a s w e l l a s t h e e n t i r e p e r i o d

f o l l o w i n g e a c h p u s h , a r e p r e s e n t e d i n T a b l e s 5.6.1-1

m h - . . v . - - o - - 7- -4 . . . . . cn n r s - i c i n r C n r .. _ - c h r - . . - h C L 1 - C . __._. - _ . _ . _ _ _ - .

p u s h e s d u r i n g t h e s a m p l i n g p e r i o d s r a n g e d f rom 40 f o r

P e a k P a r t i c u l a t e T e s t N o . 1 and C o n t i n u o u s P a r t i c u -

I

i.

l a t e T e s t No. 2 , t o 6 0 f o r P e a k P a r t i c u l a t e T e s t N O . 3 .

The f i e l d d a t a s h e e t s f rom which t h e s e v a l u e s were L

summar ized a r e p r e s e n t e d i n Appendix WW (Volume 6 ) .

The e x h a u s t d u c t o p a c i t y d a t a were u s e d f o r

t h e f o l l o w i n g p u r p o s e s :

1. To a s s e s s t h e l e n g t h o f t i m e r e q u i r e d t o

e v a c u a t e t h e c o k e - p u s h i n g e m i s s i o n s f rom

t h e s h e d ( s e e S e c t i o n 4 . 4 ) ;

- 89 -

2. To d e v e l o p c o r r e l a t i o n s w i t h :

a . G r e e n n e s s ,

b . Net c o k i n g t i m e , and

C . Ave rage c r o s s w a l l t e m p e r a t u r e ; and

3 . To d e t e r m i n e t h e r e p r e s e n t a t i v e n e s s o f

p r o c e s s c o n d i t i o n s .

5 . 6 . 2 . 2 F u g i t i v e E m i s s i o n s

O b s e r v a t i o n s o f t h e c o k e - s i d e s h e d made

d u r i n g t h e c o u r s e of t h e s t u d y i n d i c a t e d t h a t f u g i -

t i v e p a r t i c u l a t e e m i s s i o n s e s c a p e d t o p s i d e , f rom

A s k a n i a G a l v e p o s i t i o n s , and fkom b o t h e n d s o f t h e

s h e d , a s shown i n F i g u r e 3 .1-2 . The s a m p l i n g program

d e v e l o p e d t o e v a l u a t e t h i s s h e d l e a k a g e ( f u g i t i v e p a r -

t i c u l a t e e m i s s i o n s ) i n c l u d e d b o t h t he e v a l u a t i o n o f

t h e o p a c i t y o f t h e s e f u g i t i v e e m i s s i o n s and t h e u s e

o f p h o t o g r a p h s ( s t i l l s a n d m o t i o n p i c t u r e ) i n a d d i t i o n

t o p a r t i c u l a t e s a m p l i n g . B o t h t y p e s o f d a t a were

a c q u i r e d by U . S . EPA p e r s o n n e l .

The s h e d l e a k o p a c i t y d a t a a r e i n c l u d e d i n

A p p e n d i x XX (Volume 7 ) . T h e s e d a t a were u s e d t o con-

v e r t t h e peak mass e m i s s i o n r a t e s o f t h e l e a k s , wh ich

a v e r a g e d 1 - 1 / 4 m i n u t e s i n d u r a t i o n , t o a c o n t i n u o u s

( a b o u t 13 m i n u t e s ) f u g i t i v e e m i s s i o n r a t e . The p h o t o -

g r a p h s were u s e d t o e s t i m a t e t h e a v e r a g e c r o s s - s e c t i o n a l

a r e a o f t h e f u g i t i v e p lumes . T o g e t h e r w i t h t h e f u g i t i v e

p a r t i c u l a t e c o n c e n t r a t i o n d a t a d i s c u s s e d i n S e c t i o n 5 . 1 . 2 ,

t h e s e v i s u a l e s t i m a t i o n s w e r e u s e d t o d e t e r m i n e t h e con-

t i n u o u s e m i s s i o n r a t e o f f u g i t i v e e m i s s i o n s . The method-

o l o g y is d i s c u s s e d i n d e t a i l i n Append ix HH (Volume 5 ) .

- 90 - / 5 . 6 . 3 P e r c e n t o f Doors L e a k i n g

/ An a d d i t i o n a l component o f t h e c o k e - s i d e p a r t i c u l a t e

e m i s s i o n s , d o o r e m i s s i o n s , a p p e a r e d t o be p r e d o m i n a n t l y i n d e -

p e n d e n t o f e i t h e r c o k e - p u s h i n g o r quench c a r p a r t i c u l a t e emis -

s i o n s . T h e r e f o r e , an o b s e r v a t i o n t e c h n i q u e which r e c o r d e d

t h e q u a n t i t y o f oven d o o r s l e a k i n g d u r i n g a s h o r t - t e r m o b s e r -

v a t i o n p e r i o d w a s d e v e l o p e d . Any v i s i b l e l e a k f rom a d o o r

was c o n s i d e r e d a d o o r l e a k . A number o f c o k e - s i d e oven d o o r s

w e r e u s u a l l y o b s c u r e d by t h e c o k e g u i d e d u r i n g t h e s h o r t ob-

s e r v a t i o n p e r i o d , and t h e r e f o r e , t h e q u a n t i t y o f t h e s e ob-

s c u r e d d o o r s was a l s o r e c o r d e d . These o b s e r v a t i o n s y i e l d e d

a n e s t i m a t e o f t h e p e r c e n t o f c o k e - s i d e d o o r s l e a k i n g . S imi-

l a r o b s e r v a t i o n s were o b t a i n e d and r e s u l t s c a l c u l a t e d f o r t h e

p u s h s i d e o f t h e coke b a t t e r y and f o r b o t h s i d e s o f B a t t e r y

No. 2 f o r p r o c e s s d o c u m e n t a t i o n p u r p o s e s . A l l f i e l d d a t a

s h e e t s documen t ing d o o r - l e a k o b s e r v a t i o n s a r e p r e s e n t e d i n

Appendix YY (Volume 7 ) .

/

T a b l e 5 . 6 . 3 p r e s e n t s t h e d o o r - l e a k a g e d a t a f o r B a t t e r i e s

1 and 2 o n t h e d a y s o f p a r t i c u l a t e s a m p l i n g . These r e s u l t s

i n d i c a t e t h a t c o k e - s i d e o v e n d o o r l e a k a g e v a r i e d , r a n g i n g f rom

2 7 t o 6 9 p e r c e n t o n B a t t e r y No. 1 and f rom 3 9 t o 6 4 p e r c e n t on

B a t t e r y No. 2 . P u s h - s i d e o v e n d o o r l e a k a g e was somewhat l e s s

v a r i a b l e t h a n c o k e - s i d e o v e n d o o r l e a k a g e ; i t r a n g e d f rom 26

t o 37 p e r c e n t on B a t t e r y No. 1 and f rom 8 t o 1 9 p e r c e n t on Ba t -

t e r y No. 2 . F i n a l l y , p u s h - s i d e chuck d o o r l e a k a g e was t h e

l e a s t v a r i a b l e t y p e of d o o r l e a k a g e , r a n g i n g f rom 18 t o 2 2

p e r c e n t o n B a t t e r y No. 1 a n d f rom 36 t o 47 p e r c e n t on B a t t e r y

No. 2 .

._

9 1 -

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W 71 .rl m I W

9

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h

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h

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m ln v

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d I- d v

7 \ D \ D I - v N

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m *

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3 u oal

U W U a m U o m

- 9 2 -

5.7 E m i s s i o n - R e l a t e d C o r r e l a t i o n s

S i n c e t h i s p r o j e c t w a s e s s e n t i a l l y i n v e s t i g a t i v e i n n a t u r e ,

s e v e r a l p r o c e s s p a r a m e t e r s and i n d i c e s o f v i s i b l e e m i s s i o n s were

examined t o d e t e r m i n e w h e t h e r t h e y were d i r e c t l y r e l a t e d t o t h e

e m i s s i o n s m e a s u r e d . Many p o t e n t i a l c o r r e l a t i o n s were examined ,

u s i n g b o t h t h e e m i s s i o n f a c t o r o b t a i n e d from p u s h i n g o p e r a t i o n

s a m p l e s and t h e e m i s s i o n f a c t o r s o b t a i n e d from c o n t i n u o u s p a r t i c u -

l a t e s a m p l e s . S u p p o r t i v e i n f o r m a t i o n f o r t h i s s e c t i o n and a d d i -

t i o n a l a t t e m p t e d c o r r e l a t i o n s a r e p r o v i d e d i n A p p e n d i c e s 22 t o FFF

(Volumes 7 t o 1 2 ) .

5.7.1 C o r r e l a t i o n s Between E m i s s i o n F a c t o r s and I n d i c e s of V i s i b l e E m i s s i o n s

E m i s s i o n f a c t o r s f o r c o n t i n u o u s p a r t i c u l a t e s amples

were p r e s e n t e d i n T a b l e 5 . 1 . 1 . I n d i c e s o f v i s i b l e e m i s s i o n s

f o r t h e s e s a m p l e s - d e g r e e of g r e e n n e s s and o p a c i t y f o r t h e

peak e m i s s i o n p e r i o d - w e r e p r e s e n t e d i n T a b l e s 5 . 6 . 1 - 1 ,

5 . 6 . 1 - 3 , and 5 .6 .1-5 . L i n e a r c o r r e l a t i o n t e c h n i q u e s r e v e a l

n o s t a t i s t i c a l l y s i g n i f i c a n t r e l a t i o n s h i p be tween t h e t h r e e

c o n t i n u o u s f i l t e r a b l e p a r t i c u l a t e e m i s s i o n f a c t o r s and a v e r a g e

d e g r e e of g r e e n n e s s o r a v e r a g e o p a c i t y . The l i n e a r c o r r e l a t i o n

c o e f f i c i e n t s f o r t h e t h r e e p a i r s of d a t a i n v o l v e d i n t h e s e two

p o t e n t i a l r e l a t i o n s h i p s were 0 .419 and - 0 . 1 4 3 , r e s p e c t i v e l y . (*

C o r r e l a t i o n s were a l s o a t t e m p t e d u s i n g t h e t h r e e

f i l t e r a b l e p a r t i c u l a t e p u s h - o n l y e m i s s i o n f a c t o r s g i v e n i n

T a b l e 5 .1 .5 and t h e i n d i c e s o f v i s i b l e e m i s s i o n s f o r peak

p a r t i c u l a t e s a m p l e s shown i n T a b l e s 5 .6 .1 -2 , 5 . 6 . 1 - 4 , and

5.6.1-6. A g a i n , l i n e a r c o r r e l a t i o n t e c h n i q u e s y i e l d e d no

s t a t i s t i c a l l y s i g n i f i c a n t r e l a t i o n s h i p s b e t w e e n t h e s e

i

4

I .

- 9 3 -

p a r a m e t e r s . The l i n e a r c o r r e l a t i o n c o e f f i c i e n t s f o r t h e s e

p o t e n t i a l r e l a t i o n s h i p s w i t h d e g r e e o f g r e e n n e s s and o p a c i t y

w e r e 0.070 a n d 0.281, r e s p e c t i v e l y . I n e a c h o f t h e s e c a s e s ,

t h e s m a l l q u a n t i t y o f d a t a a v a i l a b l e may h a v e p a r t i a l l y

c a u s e d t h e p o o r c o r r e l a t i o n s .

5.7.2 C o r r e l a t i o n s Between E m i s s i o n F a c t o r s and P r o c e s s C o n d i t i o n s

Net c o k i n g t i m e and a v e r a g e f l u e t e m p e r a t u r e s f o r t h e

c o n t i n u o u s p a r t i c u l a t e s a m p l i n g were summar ized i n T a b l e s

5 .6 .1-1, 5 .6 .1-3 , and 5.6.1-5. C o r r e l a t i o n t e c h n i q u e s u s i n g

t h e s e p a r a m e t e r s and t h e t h r e e c o n t i n u o u s f i l t e r a b l e p a r t i c u -

l a t e e m i s s i o n f a c t o r s y i e l d e d no s t a t i s t i c a l l y s i g n i f i c a n t

r e l a t i o n s h i p s . The l i n e a r c o r r e l a t i o n c o e f f i c i e n t s f o r po-

t e n t i a l r e l a t i o n s h i p s w i t h n e t c o k i n g t i m e and a v e r a g e f l u e

t e m p e r a t u r e were -0.761 and 0,189, r e s p e c t i v e l y .

C o r r e l a t i o n s were a l s o a t t e m p t e d u s i n g t h e s e same two

p r o c e s s c o n d i t i o n s f o r peak p a r t i c u l a t e s a m p l e s and t h e t h r e e

p u s h - o n l y f i l t e r a b l e p a r t i c u l a t e e m i s s i o n f a c t o r s . A l t h o u g h

t h e l i n e a r c o r r e l a t i o n c o e f f i c i e n t f o r t h e p o t e n t i a l r e l a t i o n -

s h i p w i t h n e t c o k i n g t i m e was q u i t e h i g h , -0.949, no s t a t i s -

t i c a l l y s i g n i f i c a n t r e l a t i o n s h i p was found . When t h e l o g a -

r i t h m s o f t h e s e v a l u e s w e r e u s e d , an e v e n h i g h e r l i n e a r c o r -

r e l a t i o n c o e f f i c i e n t r e s u l t e d , -0.976. N e v e r t h e l e s s , t h i s

v a l u e , a s w e l l , was n o t s t a t i s t i c a l l y s i g n i f i c a n t , l i k e l y b e -

c a u s e o n l y t h r e e p a r t i c u l a t e s a m p l e s w e r e o b t a i n e d . The c o r -

r e l a t i o n c o e f f i c i e n t f o r t h e e m i s s i o n f a c t o r a s a f u n c t i o n o f

a v e r a g e f l u e t e m p e r a t u r e , 0 .405 , was a l s o n o t s i g n i f i c a n t .

- 9 4 -

5.7.3 C o r r e l a t i o n s I n v o l v i n g P a r t i c l e S i z e D i s t r i b u t i o n s

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 s were p r e s e n t e d g r a p h -

i c a l l y i n F i g u r e 5.4, and c h a r a c t e r i s t i c s o f t h e d i s t r i b u -

t i o n s were g i v e n i n T a b l e 5.6.1-7. Using t h e s e d a t a , l i n e a r

c o r r e l a t i o n s were a t t e m p t e d b e t w e e n t h e d i s t r i b u t i o n s and

c h a r a c t e r i s t i c s o f t h e p u s h e s . A l t h o u g h t h e c o r r e l a t i o n

c o e f f i c i e n t s w e r e q u i t e h i g h , no s t a t i s t i c a l l y s i g n i f i c a n t

c o r r e l a t i o n was a p p a r e n t b e t w e e n v a r i a t i o n s i n s i z e d i s t r i b u -

t i o n ( w e i g h t f r a c t i o n s l e s s t h a n one m i c r o n and w e i g h t f r a c -

t i o n s l e s s t h a n f i v e m i c r o n s ) d e t e r m i n e d f o r e a c h o f t h e sam-

p l e s and t h e g r e e n n e s s o f t h e push. T h i s was l i k e l y d u e t o

t h e few d a t a p a i r s a v a i l a b l e (one o f t h e f o u r s a m p l e s was

l a c k i n g g r e e n n e s s d a t a ) .

No s t a t i s t i c a l l y s i g n i f i c a n t c o r r e l a t i o n was a p p a r e n t ,

e i t h e r , b e t w e e n p a r t i c l e s i z e and n e t c o k i n g t ime . I t was

n o t p o s s i b l e t o c o r r e l a t e p a r t i c l e s i z e w i t h f l u e t e m p e r a -

t u r e s o r o p a c i t y b e c a u s e o f t h e l a c k of d a t a i n b o t h c a t e -

g o r i e s .

5.7.4 C o r r e l a t i o n s Between I n d i c e s o f V i s i b l e E m i s s i o n s and P r o c e s s C o n d i t i o n s

Two p a r a m e t e r s i n t h i s s t u d y c a n b e c o n s i d e r e d a s

i n d i c e s o f v i s i b l e e m i s s i o n s : o p a c i t y and g r e e n n e s s . The

v a l u e s f o r t h e s e two i n d i c e s d u r i n g p a r t i c u l a t e s a m p l i n g

were i n d i c a t e d i n T a b l e s 5.6.1-1 t h r o u g h 5 .6 .1-6 . Two

p a r a m e t e r s wh ich c a n be c o n s i d e r e d i n d i c a t i v e o f p r o c e s s

c o n d i t i o n s were a l s o shown i n t h e s e t a b l e s : n e t c o k i n g t i m e

and f l u e t e m p e r a t u r e . I n o r d e r t o d e t e r m i n e w h e t h e r t h e s e

_I

c

c .?

.

- 95 - i n d i c e s o f v i s i b l e e m i s s i o n s c o u l d be c o n s i d e r e d a f u n c t i o n

o f p r o c e s s c o n d i t i o n s , s e v e r a l c o r r e l a t i o n s were a t t e m p t e d .

To u s e t h e mos t c o m p l e t e d a t a b a s e p o s s i b l e , t h e d a t a i n

T a b l e s 5.6.1-1 t h r o u g h 5.6.1-6 w e r e combined w i t h t h e o t h e r

d a t a o b t a i n e d d u r i n g p a r t i c u l a t e s a m p l i n g d a y s . A l l d a t a

s e t s c a n be f o u n d i n t h e t a b l e s i n Appendix Z Z , Volume 7.

P e a k o p a c i t y was found t o b e h i g h l y c o r r e l a t e d w i t h

n e t c o k i n g t i m e d u r i n g p a r t i c u l a t e s a m p l i n g d a y s . S e v e r a l

r e l a t i o n s h i p s w e r e e v a l u a t e d u s i n g t h e s e d a t a , i n c l u d i n g t h e

l i n e a r fo rm, l o g a r i t h m s , and i n v e r s e s . A r e l a t i o n s h i p i n -

v o l v i n g i n v e r s e s , however , was f o u n d t o be s t a t i s t i c a l l y

s u p e r i o r . A m o d i f i c a t i o n t o t h e n e t c o k i n g t i m e v a r i a b l e ,

s u b t r a c t i o n o f a c o n s t a n t o f 1000 m i n u t e s , improved t h e c o r -

r e l a t i o n f u r t h e r . The c o n s t a n t f a c t o r o f 1000 was s e l e c t e d

b e c a u s e none o f t h e n e t c o k i n g t i m e s w i t n e s s e d i n a r e v i e w

o f two y e a r s o f d a t a f rom t h e Burns H a r b o r P l a n t was l e s s

t h a n t h i s v a l u e (Appendix Z Z , Volume 7 ) .

T h e , f i n a l r e g r e s s i o n f u n c t i o n , p l o t t e d i n F i g u r e

5.7.4-1, was f o u n d t o b e :

1 = 0.0386 - 0.730 1 Peak O p a c i t y

The c o r r e l a t i o n c o e f f i c i e n t f o r t h i s r e l a t i o n s h i p , wh ich com-

p r i s e d 60 p a i r s o f d a t a , was - 0 . 6 2 6 . T h i s v a l u e i s s t a t i s -

t i c a l l y s i g n i f i c a n t a t a l e v e l e x c e e d i n g t h e 9 9 - p e r c e n t

l e v e l .

A v e r y h i g h l y s t a t i s t i c a l l y - s i g n i f i c a n t c o r r e l a t i o n

was a l s o o b t a i n e d f o r g r e e n n e s s a s a f u n c t i o n of n e t c o k i n g

t i m e f o r t h e p a r t i c u l a t e s a m p l i n g d a y s . Aga in s e v e r a l fo rms

- 97 -

.. i

ah'

of the relationship were attempted, but the one relating the

inverse of greenness and the inverse of net coking time minus

a constant of 1000 was found to be superior:

The regression equation, which is plotted in Figure

5.7.4-2, was:

= 0.00510 - 0.0431 1 Greenness

The linear correlation coefficient for this relationship,

which comprised 104 sets of data, was -0.335. This coeffi-

cient is statistically significant at a level exceeding.the

9 9- percent leve 1.

Correlations were also attempted using a second process-

conditions parameter - average flue temperature. When peak

opacity was considered as a function of flue temperature, a

function involving the logarithm of temperature was found to

be superior. The regression equation, which is plotted in

Figure 5.7.4-3, was:

Peak Opacity = 4122 - 523 [ln(Temp)l . The correlation coefficient for this relationship, which in-

volved 24 sets of data, was -0.655. This value is signifi-

cant at a level exceeding the 99-percent level.

A potential relationship between greenness and flue

temperature was also considered. The linear relationship

between the logarithms of both values was found t o be supe-

rior. The equation, which i s plotted in,Figure 5.7.4-4, was:

ln(Greenne6s) = 75.8 - 9.04 [ln(Temp] .

t

I,

i

Y .,

- 1 0 1 -

The c o r r e l a t i o n c o e f f i c i e n t f o r t h i s r e l a t i o n s h i p , wh ich

i n v o l v e d 31 p a i r s o f d a t a , w a s -0.709. T h i s v a l u e i s s t a -

t i s t i c a l l y s i g n i f i c a n t a t a l e v e l e x c e e d i n g t h e 9 9 - p e r c e n t

l e v e l .

5.7.5 C o r r e l a t i o n s Among V i s i b l e E m i s s i o n s Measuremen t s

A t t e m p t e d c o r r e l a t i o n s i n v o l v i n g o p a c i t y a s a f u n c -

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

r e s u l t e d i n a h i g h l y s t a t i s t i c a l l y - s i g n i f i c a n t c o r r e l a t i o n .

The f i n a l e q u a t i o n , wh ich i s p l o t t e d i n F i g u r e 5 . 7 . 5 - l , . w a s :

Peak O p a c i t y = -166 + 39.0 [ l n ( G r e e n n e s s g . The c o r r e l a t i o n c o e f f i c i e n t f o r t h i s r e l a t i o n s h i p , c o v e r i n g

54 s e t s o f d a t a , was 0 . 6 4 6 ; t h e s t a t i s t i c a l s i g n i f i c a n c e o f

t h i s v a l u e e x c e e d s t h e 9 9 - p e r c e n t l e v e l .

In o r d e r t o f u r t h e r e v a l u a t e t h e o p a c i t y o f t h e emis -

sions f r o m t h e s h e d e x h a u s t s t a c k , t h e o p a c i t y d a t a o b t a i n e d

d u r i n g p a r t i c u l a t e s a m p l i n g d a y s were combined w i t h a l l

a v a i l a b l e o p a c i t y d a t a t a k e n by c e r t i f i e d v i s i b l e e m i s s i o n

o b s e r v e r s d u r i n g a o n e - y e a r p e r i o d p r i o r t o t h e s t a r t o f

t h e f i e l d t e s t i n g . The r e s u l t s w e r e t h e n g r o u p e d i n two

ways. The f i r s t method c l u s t e r e d t h e d a t a i n t o t h e f o u r

c a t e g o r i e s l i s t e d be low:

1. P a r t i c u l a t e t e s t d a y s ( t y p i c a l , n o r m a l c o n d i t i o n s

o n l y ) ;

2. N o n - t e s t d a y s ( t y p i c a l , n o r m a l c o n d i t i o n s o n l y ) ;

3. T y p i c a l b u t a b n o r m a l c o n d i t i o n s ( i . e . , c o k e -

p u s h i n g c y c l e d u r a t i o n e x c e e d i n g 30 m i n u t e s ) ; and

4 . T y p i c a l b u t a b n o r m a l c o n d i t i o n s ( i . e . , n e t c o k i n g

t i m e g r e a t e r t h a n 1 8 - 1 / 2 h o u r s ) .

- 102 -

- 1 0 3 - The o p a c i t y d a t a , t a k e n a t i n t e r v a l s o f a p p r o x i m a t e l y 1 5

s e c o n d s , were t h e n a v e r a g e d f o r e a c h o f t h e s e f o u r c a t e g o r i e s .

The r e s u l t s a r e p l o t t e d i n F i g u r e 5.7.5-2. The numbers i n

p a r e n t h e s e s above e a c h l i n e o n t h e g r a p h i n d i c a t e t h e number

o f s e t s o f d a t a a v e r a g e d t o o b t a i n t h e c u r v e .

To i n v e s t i g a t e t h i s r e l a t i o n s h i p f u r t h e r , t h e d a t a

w e r e r e g r o u p e d b a s e d upon n e t c o k i n g t i m e . S i x 1 5 - m i n u t e

n e t c o k i n g t i m e i n t e r v a l s w e r e e s t a b l i s h e d , u s i n g t h e 1 ,035-

m i n u t e minimum n e t c o k i n g t i m e s p e c i f i e d by B e t h l e h e m S t e e l

C o r p o r a t i o n a s a b a s e l i n e . The r e s u l t s a r e p l o t t e d i n F i g u r e

5.7.5-3. A g a i n , t h e numbers i n p a r e n t h e s e s a b o v e e a c h l i n e

o n t h e g r a p h i n d i c a t e t h e number o f d a t a s e t s a v e r a g e d t o

o b t a i n t h e c u r v e . T h i s f i g u r e i n d i c a t e s t h a t i n c r e a s i n g n e t

c o k i n g t i m e y i e l d s p r e d i c t a b l y d e c r e a s i n g shed e x h a u s t o p a c -

i t i e s .

5.8 E f f e c t o f t h e Shed Upon D u s t f a l l

I n a d d i t i o n t o c o l l e c t i n g d o o r , quench c a r movement, and push -

i n g e m i s s i o n s , t h e s h e d on B a t t e r y No. 1 a l s o a c t s a s a l a r g e s e t -

t l i n g chamber f o r c o a r s e d u s t , e s p e c i a l l y a l o n g t h e s h e d w a l l .

D u r i n g a p u s h , and f o r a p e r i o d o f a b o u t two o r t h r e e m i n u t e s

t h e r e a f t e r , a w o r k e r o r o b s e r v e r u n d e r t h e s h e d may e x p e r i e n c e

a " f a l l o u t " o f s e t t l e a b l e p a r t i c u l a t e m a t t e r a l o n g t h e l e n g t h o f

t h e s h e d , e s p e c i a l l y a l o n g t h e shed w a l l .

To d e t e r m i n e t h e m a g n i t u d e o f t h i s e f f e c t , a n d t o d e t e r m i n e

how i t v a r i e s w i t h l o c a t i o n , d u s t f a l l ( s e t t l e a b l e p a r t i c u l a t e )

m e a s u r e m e n t s w e r e made on and a b o u t b o t h B a t t e r i e s 1 and 2. Dus t -

f a l l j a r s w e r e e x p o s e d a t f i x e d l o c a t i o n s on b o t h b a t t e r i e s :

- 104 -

Average Opaci ty

F I G U R E 5 . 7 . 5 - 2

5COMPOSITE GRAPH OF SHED EXHAUST DUCT OPACITY VERSUS TIME

Burns Harbor P l a n t Bethlehem S t e e 1 . C o r p o r a t i o n

C h e s t a r t o n , I n d i a n a March 3 - 7 , 1975

T i m e After Commencement o f Push ( s e c o n d s ) Clayton Environmental C o n s u l t a n t s , I n c .

- 105 - F I G U R E 5.7.5-3

Time A f t e r Commencement o f Push ( s e c o n d s )

Clayton Environmental Const i i tants , Inc;

- 106 -

1. Along t h e bench o f B a t t e r y 1 ( u n d e r t h e s h e d ) ;

2. Along t h e bench o f B a t t e r y 2 ( u n s h e d d e d ) ;

3. Along t h e s h e d w a l l o f B a t t e r y 1, a b o u t 30 f e e t f rom

t h e s i d e o f t h e b e n c h ; a n d

4. Along a l i n e g e o m e t r i c a l l y e q u i v a l e n t t o t h a t d e s c r i b e d

i n (3) a b o v e , n e a r B a t t e r y 2.

It s h o u l d be k e p t i n mind t h a t t h i s t e c h n i q u e p r o v i d e s o n l y r e l a -

t i v e v a l u e s o f d u s t f a l l i n t e n s i t y .

T a b l e 5.8-1 shows d u s t f a l l d a t a f o r c o m p a r a b l e l o c a t i o n s on

B a t t e r i e s 1 a n d 2. The u n i t s i n e a c h c a s e a r e g r a m s / m 2 / w e e k . ( c o n -

v e r t i b l e t o t h e u s u a l " a m b i e n t " u n i t s o f t o n s / m i 2 / m o n t h by m u l t i -

p l y i n g by 11.4). The g e o m e t r i c mean v a l u e f o r e a c h l o c a t i o n i s

a l s o r e p o r t e d . A l l d u s t f a l l s a m p l i n g p e r i o d s , d u s t f a l l w e i g h t s ,

and t h e p e r c e n t a g e o f p a r t i c u l a t e m a t t e r c o l l e c t e d o n t h e s i e v e

a r e p r e s e n t e d i n Appendix GGG (Volume 1 2 ) .

I n c o m p a r i n g t h e d a t a i n T a b l e 5.8-1, s e v e r a l g e n e r a l comments

s h o u l d be k e p t i n mind :

1. P u s h i n g e m i s s i o n r a t e s f o r t h e s e t w o c o k e b a t t e r i e s a r e

not n e c e s s a r i l y i d e n t i c a l . The b a t t e r i e s a r e o f d i f f e r -

e n t d e s i g n w i t h r e s p e c t t o t h e i r h e a t i n g s y s t e m , B a t t e r y

2 b e i n g newer .

2. B a t t e r y 1 p r o d u c e s a b o u t 1 0 p e r c e n t more c o k e p e r h o u r .

3. V a r i a t i o n s i n wind s p e e d a n d d i r e c t i o n may a f f e c t t h e

s i g n i f i c a n c e o f t h e d a t a .

A s h e d v i s i t o r ' s p e r c e p t i o n t h a t d u s t f a l l i s s e v e r e u n d e r a

s h e d s h o u l d b e i n t e r p r e t e d i n t h e c o n t e x t o f t h e p h y s i c a l p o s i t i o n

o f t h e o b s e r v e r . I t i s common f o r s u c h o b s e r v a t i o n s t o be made a t

g round l e v e l n e a r o r u n d e r t h e s h e d w a l l on t h e f a r s i d e o f t h e

. . i

- 1 0 7 - - TABLE 5 .8-1

SUMMARY OF DUSTFALL MEASUREMENTS A T B A T T E R I E S 1 A N D 2

Burns H a r b o r P l a n t Be th lehem S t e e l C o r p o r a t i o n

Ches t e r t o n , I n d i a n a March 3 - 7 , 1975

(gmIm2lwk)

.3

c,

.,/

.,

,'

Sampl ing 1975 S a m p l i n g P e r i o d L o c a t i o n

r 313-4 I 314 I 314-5 I 315 I 315-6 I 316

Shedded I S p a r e Door I 1660 I 3700 1 3260 I 3080 I 332

Uns he dd ed + I I I S p a r e Door I 1 9 8 1 5 6 1 275 Bench 1 2 3 I - 3300

~ ~~

G e o m e t r i c Mean I 2020 I 3000 1 3 9 1 0

Ground 251 +

Shedded W a l l I I I 1 1 1 . 6 0 0 111 .400 1 1 2 . 5 0 0 n W a l l 1 2 1

Mid 1** 3180 4110 - Mid 2 1380 5850 - A

Shedded Mid

Mid 1** 3180 4110 - Mid 2 1380 5850 - A

Shedded Mid

3590 5000

4160 4470

1710 2000 2300 4010 2320 :::l 1 2190 1 3220

27,800 22 ,200 25 ,200 11 ,100 3 0 , 4 0 0

1 8 , 4 0 0 1 6 , 3 0 0 10 ,600

3370 2410

3460 - 2390 G e o m e t r i c Mean 2090 4900 - End l,, 1530 1530 - 1630 - 3640

1780 - 1670

, End 2 A 1280 2560 -

Geometrii ' Mean - 1830

286

3320 3810 3800

3620

P

2510 2730 2890

2690

24 ,600 1 3 , 1 0 0

1 7 , 5 0 0

364 494 250

365

-

1 3 , 2 0 0

3240 2850

- 3040

1930 1770

- I I I 1

Shedded End G e o m e t r i c Mean 1400 1980 - 1700 - 2430 1850

They were * S t a t i s t i c a l t e s t s i n d i c a t e t h a t t h e s e v a l u e s a r e s u s p e c t . n o t u sed i n t h e s t a t i s t i c a l a n a l y s e s .

** D u p l i c a t e Samples

A B a t t e r y No. 1 + B a t t e r y No. 2 C l a y t o n E n v i r o n m e n t a l C o n s u l t a n t s , I n c .

- 108 -

quench ca r t r a c k s . F o r r e a s o n s o f a c c e s s i b i l i t y and s a f e t y , i t is

e a s i e r t o o b s e r v e t h e r e t h a n on t h e c o k e - s i d e b e n c h , which o f f e r s

no c l e a r a n c e b e t w e e n a b a t t e r y and i t s d o o r machine . D u s t f a l l

u n d e r t h e w a l l i s n o t n e c e s s a r i l y r e p r e s e n t a t i v e o f a work s t a -

t i o n , i . e . , normal w o r k e r e x p o s u r e .

I n a d d i t i o n , t h e s m a l l n u m e r i c a l d i f f e r e n c e i n T a b l e 5 . 8 - 1

b e t w e e n d u s t f a l l r a t e s a t bench l o c a t i o n s on t h e shedded and un-

shedded b a t t e r i e s means t h a t t h e s h e d had no a p p a r e n t m e a s u r a b l e

e f f e c t on d u s t f a l l a t t h i s key work s t a t i o n .

T a b l e 5 .8-2 p r e s e n t s t h e a c e t o n e - s o l u b l e and c y c l o h e x a n e -

s o l u b l e c o n t e n t o f f i v e s e l e c t e d d u s t f a l l s a m p l e s . N e i t h e r e x -

t r a c t i o n r e s u l t e d i n a c o n c e n t r a t i o n wh ich e x c e e d e d 0.1 p e r c e n t .

T a b l e 5 .8-3 p r e s e n t s t h e pH o f f i v e o t h e r s a m p l e s ; t h e v a l u e s

r a n g e d f rom 6.0 t o 7.1.

In o r d e r t o i d e n t i f y how t h e c o k e - s i d e s h e d a f f e c t s m e a s u r -

a b l e d u s t f a l l r a t e s , o t h e r p o t e n t i a l i n f l u e n t i a l f a c t o r s were

f i r s t e v a l u a t e d . These o t h e r v a r i a b l e s w e r e : a ) g r e e n n e s s o f

t h e p u s h e s , b ) p u s h i n g r a t e , and c ) l o c a t i o n o f t h e d u s t f a l l

b u c k e t . The d a t a shown in T a b l e 5 .8-1 were u s e d f o r t h e a n a l y s e s .

A l l s t a t i s t i c a l a n a l y s e s were p e r f o r m e d u'sing t h e l o g a r i t h m s o f

t h e d u s t f a l l r a t e s s i n c e d u s t f a l l r a t e s a r e known t o be l o g - n o r -

m a l l y d i s t r i b u t e d . ( 4 )

Because d u s t f a l l measu remen t s i n h e r e n t l y a r e r e l a t i v e l y c r u d e ,

t h e p r e c i s i o n ( r e p r o d u c i b i l i t y ) o f t h e method was e s t i m a t e d by

e x p o s i n g p a i r s o f d u s t f a l l j a r s a t t h e same s i t e . The e i g h t

p a i r s o f s a m p l e s i d e n t i f i e d in T a b l e 5 . 8 - 1 a s " m i d " and "end"

J

- 1 0 9 -

S i t e

Ground 1 7 7

W a l l 1 2 1

Bench 278

Bench 223

Bench 1 5 2

TABLE 5.8-2

SUMMARY OF ACETONE SOLUBLE AND CYCLOHEXANE SOLUBLE C O N T E N T

OF SELECTED DUSTFALL SAMPLES

B u r n s H a r b o r P l a n t B e t h l e h e m S t e e l C o r p o r a t i o n

C h e s t e r t o n , I n d i a n a March 3 - 7 , 1 9 7 5

S a m p l i n g P e r i o d P e r c e n t P e r c e n t

S o l u b l e s S o l u b l e s S t a r t - s t o p Ace tone Cyc lohexane

Da te T i m e Da te T i m e

313 1 6 : 4 7 314 0 9 : 1 7 0 .008 0 .002

313 1 6 : 3 1 314 09:05 0.002 0 .004

314 0 8 : 2 6 314 1 5 : 4 9 0 .005 0 .006 .

314 1 5 ~ 4 4 315 10 :19 0.087 0 . 0 1

316 0 9 : 5 2 316 1 7 : 4 6 0.042 0 .02

C l a y t o n E n v i r o n m e n t a l C o n s u l t a n t s , Inc .

~ ~~ _ _ _ _ ~

TABLE 5.8-3

SUMMARY OF pH OF S E L E C T E D DUSTFALL SAMPLES

Burns .Ha r bor' . P l a n t Bethlehem S t e e l Corporat ion

C h e s t e r t o n , Indiana March 3-7, 1975

Bench 152

Ground 151

Sampling Per iod

s tJ

Date - 314

313

316

313

314

08: 17 15:30

16 10

09 01

17: 1 2 0 9 : 18

10: 35 16:30

pH of Sample

6.6

6.2

7 . 1

6.0

7.1

Clayton Environmental C o n s u l t a n t s , I n c .

- 111 -

.1

CJ

.I

./

.3

s a m p l e s were s i m u l t a n e o u s p a i r s . To d e t e r m i n e t h e p r e c i s i o n o f

e a c h o f t h e s e p a i r s o f s a m p l e s , t h e d i f f e r e n c e i n t h e l o g a r i t h m s

o f t h e p a i r e d v a l u e s was d i v i d e d b y t h e g e o m e t r i c mean o f t h e

p a i r . These p r e c i s i o n v a l u e s r a n g e d f rom 0.2 t o 11 p e r c e n t .

These e i g h t p r e c i s i o n v a l u e s were t h e n e v a l u a t e d t o d e t e r m i n e if

any p a i r c o u l d be c o n s i d e r e d a n " o u t l i e r . " No p a i r o f s a m p l e s

c o u l d b e c l a s s i f i e d a s a n o u t l i e r by t h i s method. I n a l l a d d i -

t i o n a l e v a l u a t i o n s , t h e g e o m e t r i c mean d u s t f a l l r a t e was t h e n

u s e d f o r t h e p a i r e d s a m p l e s . The "mid" and "end" s a m p l e s a r e

i n d i c a t e d i n f u r t h e r a n a l y s e s a s "ground" s a m p l e s t a k e n a t t h e

4 - f o o t l e v e l .

An a v e r a g e g r e e n n e s s f o r o v e n s pushed d u r i n g e a c h d u s t f a l l

s ample was d e t e r m i n e d by a v e r a g i n g t h e "sum t i m e s d u r a t i o n " v a l u e s

f o r t h e p u s h e s t h a t o c c u r r e d d u r i n g t h e s a m p l i n g p e r i o d . These

a v e r a g e g r e e n n e s s v a l u e s were t h e n a r r a n g e d i n a s c e n d i n g o r d e r

and a median v a l u e o f 230 found. A l l g r e e n n e s s v a l u e s be low 230

were l a b e l e d "low" and a l l above 230 were l a b e l e d "h igh ." I t i s

i m p o r t a n t t o n o t e t h a t 7 7 p e r c e n t o f t h e p u s h e s u n d e r t h e s h e d

had h i g h a v e r a g e g r e e n n e s s v a l u e s w h i l e o n l y 14 p e r c e n t o f t h e

unshedded p u s h e s h a d a v e r a g e g r e e n n e s s v a l u e s t h a t w e r e con-

s i d e r e d h i g h .

P u s h i n g r a t e f o r a d u s t f a l l s a m p l e was d e t e r m i n e d by c o u n t -

i n g t h e number o f e i t h e r shedded o r unshedded o v e n s , a s a p p l i c a b l e ,

t h a t were pushed d u r i n g a sample and d i v i d i n g by t h e t i m e d u r a t i o n

o f t h e d u s t f a l l sample . Again t h e v a l u e s were a r r a n g e d i n a s c e n d -

i n g o r d e r and t h e med ian was found t o b e 4.7 p u s h e s p e r h o u r .

All p u s h i n g r a t e s b e l o w t h i s v a l u e were c o n s i d e r e d "low" and a l l

r a t e s e q u a l t o o r above t h i s v a l u e were c o n s i d e r e d "h igh ."

- - 112 -

The d u s t f a l l d a t a w e r e t h e n a r r a n g e d i n t o s e v e r a l c e l l s i n

o r d e r t o b e s t e l i m i n a t e a n y c o n f o u n d i n g e f f e c t o f t h e m u l t i p l e

v a r i a b l e s . These c e l l s , shown i n T a b l e 5 .8-4, w e r e d e t e r m i n e d by

f i r s t d i v i d i n g t h e d a t a i n t o t h a t a p p l i c a b l e t o s h e d d e d and un-

shedded a r e a s . Each a r e a was s u b d i v i d e d i n t o o n e o f f o u r common

l o c a t i o n s : " s p a r e d o o r , " "bench , " "g round" a t t h e 4-fOOt l e v e l ,

or "ground" a t t h e 1 0 - f o o t l e v e l . O t h e r l o c a t i o n s sampled i n

t h i s s t u d y were n o t u s e d i n t h e a n a l y s e s b e c a u s e s a m p l e s t a k e n

a t t h e s e l o c a t i o n s were t a k e n o n l y w i t h i n t h e shed . The n e x t two

s u b d i v i s i o n s were t h o s e o f "low" and "h igh" p u s h i n g r a t e s and

"low" and " h i g h " g r e e n n e s s e s . Tes t s f o r o u t l i e r s w e r e t h e n con-

d u c t e d w i t h i n e a c h o f t h e s e c e l l s ; a s i n g l e c e l l now c o n t a i n e d

t h e most homogeneous s u b s e t o f d a t a a v a i l a b l e . Only t h e t h r e e

v a l u e s i n d i c a t e d i n T a b l e s 5 . 8 - 1 and 5 .8-4 were found t o b e o u t -

l i e r s .

I n o r d e r t o d e t e r m i n e w h e t h e r g r e e n n e s s and d u s t f a l l r a t e

were c o r r e l a t e d , t h e number o f s u b d i v i s i o n s was r e d u c e d by one s o

c h - c n r e e n n e a c T.YZ+O nn l n n o o r rvmod a s a h a a f a of a l lhdf .v i . s ion . I n

e a c h o f t h e r e m a i n i n g 16 c e l l s , t h e l o g a r i t h m o f d u s t f a l l r a t e

f o r e a c h s a m p l e was p a i r e d w i t h i t s a v e r a g e g r e e n n e s s v a l u e . The

l i n e a r c o r r e l a t i o n c o e f f i c i e n t f o r t h e p a i r s i n e a c h c e l l was t h e n

d e t e r m i n e d . Only t h e v a l u e f o r t h e n i n e shedded bench s a m p l e s

w i t h low p u s h i n g r a t e s was found t o be s i g n i f i c a n t a t t h e 9 5 - p e r c e n t

l e v e l . On t h e b a s i s o f t h e f a c t t h a t o n l y one o f t h e c o r r e l a t i o n

c o e f f i c i e n t s was found t o be s i g n i f i c a n t , i t was c o n c l u d e d t h a t

t h e r e l a t i o n s h i p b e t w e e n g r e e n n e s s and d u s t f a l l r a t e was n o t s i g -

n i f i c a n t f o r t h e o v e r a l l d a t a s e t .

I -

-

Y

5

- 113 - TABLE 5.8-4

FORMAT USED FOR ANALYSES OF DUSTFALL DATA (gmIm2Iwk)

Burns Harbor Plant Bethlehem Steel Corporation

Chest erton , Indiana March 3-7, 1975

56 3 5 2 2 2 2

6,010 2,000 2,300 1,500 3,380 2,540

26 , 900* 4,640 2,320 2,080 4,500

1,130 5*

120 645 739 492 5 76

i

2,32C

1,71c 4,OlC

1,OlC

Gre ennes s

Pushing - Rate

Spare Door

Bench

Ground (4' 1 eve 1 )

Ground (10' level)

S h e d d e d

Low

Low

1,660 -

2,690 2,410 3,790

4,900 1,980

!1,900 15,300 11,400

Iigh - -

High

Low

3', 700 3,260 3 , 080 3 , 300 4,810 3,650 6,270 3 , 050 3,590

484*

3,460 1,700

27,800 22,200 L1,200

L1,lOO 7 , 340 12,500 18,400 16,300

High - 3 3 2

2,840 5 , 000

2,390 2,470

25,200 30,400 10,600

U n s h e d d e d

LOW - 275

3,800

- 136 137

* Statistical tests indicate that these values are suspect. They were not used in statistical analyses completed after the test for outliers.'

Clayton Environmental Consultants, Inc.

~ ~ ~~ ~

- 114 -

Since greenness and dustfall rate were not found to be cor-

related, those dustfall rates which did not have a greenness

rating associated with them could now be included in further

analyses. Thus, these values were added to their respective

cells determined in the previous analysis, and the tests for out-

liers were repeated. No additional suspect values were found.

The correlation between pushing rate and dustfall rate was

evaluated next in a similar manner. The number of subdivisions

was reduced by one by eliminating pushing rate as a basis of sub-

division. I n each of the remaining eight cells, the logarithm of

dustfall rate was paired with its pushing rate. The linear corre-

lation coefficient was determined for each cell. None of the

values was found to be significant at the 95-percent level. It

was thus concluded that pushing rate and dustfall rate were not

correlated for this set of data.

Two factors remained to be considered - the location of the dustfall bucket and the shed effect, i.e., shedded versus unshed-

ded areas. To determlne wnecner or noc ~ o c a c i u u w a a a a i s t , ~ ~ ~ ~ ~ ~ . ;

factor, two separate one-way analyses of variance were performed.

The door-bench-ground location samples were compared to each other

for the shedded and unshedded areas. Under the shed, the geo-

metric mean of the 10-foot-level ground samples was significantly

. * .

,I

.L

higher than that of the other three locations. The geometric mean

of the bench samples, in turn, was significantly higher than the

geometric mean of the spare door samples. The geometric mean of

the 4-foot-level ground samples did not differ significantly from

that of the bench samples or the spare door samples.

-

- 115 -

.

.

For the unshedded area, the geometric mean of the bench sam-

ples was found to be significantly higher than the geometric means

of the 4-foot-level ground samples and the spare door samples. In

this area, the geometric mean dustfall rates for the ground sam-

ples and the spare door samples were essentially the same.

Since location of the dustfall bucket appeared to be a sig-

nificant factor, a one-way analysis of variance was done for each

of the locations to determine whether or not the shed was a sig-

nificant factor. At three of the four locations -the spare doors

and both ground levels -the geometric mean dustfall rates under

the shed were found to be significantly higher than those for sam-

ples not taken under the shed. However, for the bench location

the geometric mean dustfall rates under the shed were not statis-

tically different from those found at the unshedded location. It

can thus be concluded that both the presence of the shed and the

location of the dustfall bucket have a significant influence upon

measured dustfall rates i n this study.

5.9 Impact of the Shed Upon Airborne Agents Within the Shed

The question of whether a semienclosed shed adjacent to a

coke-oven battery has a significant effect upon the quality of

the work environment within the shed was not addressed i n this

study. Two studies by the National Institute of Occupational

Safety and Health (NIOSH), however, did address this issue. (5,6)

5.10 Precision of Test Results

Although the terms "precision" and "accuracy" are often re-

garded as synonymous, they do have different technical meanings.

The accuracy of a measurement signifies the closeness with which

- 116 -

the measurement approaches the true value. Precision, on the

other hand, characterizes the repeatability of the measurements.

Thus, the precision of a measurement denotes the closeness with

which a given measurement approaches the average of a series of

measurements taken under similar conditions. Clearly, if the

bias is large, a measurement may be very precise but very inac-

curate.

Many techniques exist to evaluate the precision of a result.

Ideally, simultaneous replicate samples are taken and the coeffi-

cient of variation, the standard deviation expressed as a percent-

age of the mean, is used as a measure of precision. This technique

was used for eight pairs of dustfall samples taken in this study

and reported in Section 5.8.

When the sample at hand is the only measure of the variability

of data at given conditions, a confidence interval may be used to

bracket the true mean of the population. This interval may be re-

garded as a first estimate of the precision of the results. In

this study, such confidence intervals were constructed at the 95-

percent level, implying a 5-percent risk of not bracketing the true

mean of a series of test measurements. This confidence interval is

expressed in the Summary and Conclusions (Section 2.0) as m (+ r),

where m is the arithmetic mean and 2r is the confidence interval.

This technique was used in the evaluation of particulate emission

rates and emission factors.

-

This report prepared by: Thomas A. Loch, Ph.D., P.E. John E. Mutchler, P.E. Richard J. Powals, P.E. Janet L. Vecchio

.> S

., 1

.

.

- 117 -

6.0 REFERENCES

1. U n i t e d N a t i o n s R e p o r t , Economic Commission f o r E u r o p e ,

" A i r . P o l l u t i o n by Coking P l a n t s ,I' ST/ECE/Coa l /26 , 1968 .

2. U.S. EPA, D i v i s i o n o f S t a t i o n a r y S o u r c e E n f o r c e m e n t , "S tudy

o f Coke-Side Coke-Oven E m i s s i o n s , G r e a t L a k e s Carbon C o r p o r a -

t i o n , S t . Louis, M i s s o u r i , " i n p r i n t .

3. C o n n e r , W . D . and J . R . H o d k i n s o n , O p t i c a l P r o p e r t i e s a n d

V i s u a l E f f e c t s o f Smoke S t a c k P l u m e s , U.S. EPA, O f f i c e o f

P r o g r a m s , P u b l i c a t i o n No. AP-30, May, 1972 .

4 . TR-2 A i r P o l l u t i o n Measurement Commi t t ee , "Recommended

S t a n d a r d Method f o r C o n t i n u i n g D u s t f a l l S u r v e y (APM-1,

R e v i s i o n 1) ," J o u r n a l o f A i r P o l l u t ' i o n C o n t r o l A s s o c i a t i o n ,

1 6 : 7 , pp. 372-377 , 1966 .

5 . N a t i o n a l I n s t i t u t e f o r O c c u p a t i o n a l S a f e t y and H e a l t h ,

D i v i s i o n o f T e c h n i c a l S e r v i c e s , I n d u s t r i a l Hygiene S e r v i c e s

B r a n c h , "An I n d u s t r i a l Hygiene S u r v e y o f t h e B e t h l e h e m S t e e l

C o r p o r a t i o n ( B u r n s H a r b o r F a c i l i t y ) Coke S i d e E m i s s i o n

C o l l e c t i n g Shed , " P r o j e c t No. 75-32 , A p r i l 2 8 , 1975 .

6 . N a t i o n a l I n s t i t u t e f o r O c c u p a t i o n a l S a f e t y and H e a l t h ,

D i v i s i o n o f T e c h n i c a l S e r v i c e s , I n d u s t r i a l Hyg iene S e r v i c e s

B r a n c h , "An I n d u s t r i a l Hyg iene S u r v e y o f t h e G r e a t L a k e s

Carbon C o r p o r a t i o n ( M i s s o u r i Coke & Chemica l D i v i s i o n ) Coke

S i d e E m i s s i o n C o l l e c t i n g S h e d , " P r o j e c t No. 75-31 ,

A p r i l 2 8 , 1 9 7 5 .

- 118 -

7.0 SOME ANTICIPATED QUESTIONS A N D ANSWERS R E L A T I V E TO THIS PROJECT

--

.I

1. Q . Were t h e s e e m i s s i o n t e s t s t r u l y r e p r e s e n t a t i v e o f t h e t y p i -

c a l c o n d i t i o n s o c c u r r i n g a t Coke B a t t e r y No. 1 a t t h e B u r n s

H a r b o r p l a n t ?

A . Yes. A g r e a t d e a l o f c a r e was t a k e n and much d o c u m e n t a t i o n

was o b t a i n e d t o e n s u r e t h a t b o t h t h e p r o c e s s o p e r a t i o n s and

t h e s a m p l i n g and a n a l y t i c a l p r o c e d u r e s would a c c u r a t e l y

r e p r e s e n t t y p i c a l c o n d i t i o n s e x i s t i n g a t t h e s u b j e c t b a t t e r y

( s e e S e c t i o n 3.2).

2 . Q. J u s t how r e a s o n a b l e is t h e c h o i c e "+ 10%" f o r d e f i n i n g - t y p i c a l c o n d i t i o n s ?

A . Q u i t e r e a s o n a b l e . B a s i c a l l y , two o f f - s e t t i n g c o n d i t i o n s

a r e a t work . One is t h e i n h e r e n t v a r i a b i l i t y o f p r o c e s s

p a r a m e t e r s and t h e o t h e r is t h e need f o r m a i n t a i n i n g , a s

c lo se a s p o s s i b l e , maximum o p e r a t i n g c o n d i t i o n s d u r i n g t h e

t e s t p e r i o d wh ich a r e r e p r e s e n t a t i v e o f "normal" c o n d i -

t i o n s . We b e l i e v e t h a t + 5% is p r o b a b l y t o o s t r i c t a c r i -

t e r i o n f o r p r o c e s s v a r i a b l e s w h i c h would n o t m a t e r i a l l y

a f f e c t t h e outcome of t e s t i n g . However , a n y t h i n g more t h a n

- + 10% c o u l d v e r y l i k e l y c a u s e s i g n i f i c a n t c h a n g e s i n emis-

s i o n c o n c e n t r a t i o n s , r a t e s , and c h a r a c t e r i s t i c s . T h e r e f o r e ,

t h e c r i t e r i o n o f + 10% was c h o s e n t o r e p r e s e n t " t y p i c a l "

c o n d i t i o n s .

-

-

3. Q . Were t h e f r e q u e n c y and e x t e n t o f o u r o b s e r v a t i o n s s u f f i c i e n t

t o c h a r a c t e r i z e t h e p a r t i c u l a t e e m i s s i o n s a s a f u n c t i o n o f

p r o c e s s i n p u t r a t e ?

3 . A .

4 . Q.

A .

5. Q.

A .

- 119 - W h i l e e m i s s i o n f a c t o r s a n d e m i s s i o n r a t e s d i d n o t c o r r e l a t e

s i g n i f i c a n t l y w i t h p r o c e s s i n p u t r a t e , some r e l a t e d c o r r e l a -

t i o n s were found t o be s i g n i f i c a n t s t a t i s t i c a l l y . Those

c o r r e l a t i o n s r e l a t i n g t h e i n d i c e s o f v i s i b l e e m i s s i o n s t o

v a r i o u s p r o c e s s p a r a m e t e r s , s u c h a s n e t c o k i n g t i m e , p roved

s i g n i f i c a n t . The f a c t t h a t e m i s s i o n f a c t o r s o r e m i s s i o n

r a t e s c o u l d n o t be c o r r e l a t e d t o p e r t i n e n t p r o c e s s param-

e t e r s i s due p r e d o m i n a n t l y t o t h e s m a l l number o f d a t a

p o i n t s a v a i l a b l e ( t h r e e ) f o r e m i s s i o n measu remen t t e s t s .

Because s o much o f t h e d a t a a c q u i r e d d u r i n g t h e s e s o u r c e

t e s t s a p p e a r s t o be r e l a t i v e l y p r e c i s e , s e v e r a l c o r r e l a -

t i o n s were examined n o n e t h e l e s s .

2

#

-4

-

Why was t h e t e r m " t o n s o f d r y c o a l f e d " used a s a n o r m a l i -

z a t i o n f a c t o r ?

Dry c o a l f e e d r a t e r a t h e r t h a n w e t c o a l f e e d r a t e was used

b e c a u s e i t was a n a c c u r a t e measu remen t and c o m p a t i b l e w i t h

a mass b a l a n c e c o n c e p t w h i c h h i s t o r i c a l l y h a s b e e n t h e

" p r o c e s s w e i g n t r a t e ' ' method or n o r m a l i z i n g e m i s s i o n d a t a

t o p r o d u c t i o n r a t e .

Does t h e Burns H a r b o r s t u d y p r o v i d e s u f f i c i e n t b a s i s f o r

e x p r e s s i n g a n e m i s s i o n f a c t o r f o r c o k e - s i d e e m i s s i o n s ?

The Burns H a r b o r t e s t s p r o v i d e e m i s s i o n f a c t o r s f o r coke-

s i d e e m i s s i o n s f o r a h o s t of c o n t a m i n a n t s f o r a s i n g l e

coke-oven b a t t e r y a t a s i n g l e p r o d u c t i o n r a t e and a r e l a t i v e l y

n a r r o w r a n g e o f o p e r a t i n g c o n d i t i o n s . N o n e t h e l e s s , t h e

d e g r e e t o wh ich d a t a a n a l y s i s h a s r e v e a l e d s t a t i s t i c a l l y

s i g n i f i c a n t c o r r e l a t i o n s b e t w e e n e m i s s i o n f a c t o r s and

?

. f

- 120 -

6 . Q.

A .

7 . Q.

A .

p r o c e s s p a r a m e t e r s i n d i c a t e s t h a t e x t r a p o l a t i o n o f t h e s e

r e s u l t s t o o t h e r b a t t e r i e s may be a p p r o p r i a t e and mean ing-

f u l o n l y i f s i m i l a r r a n g e s o f p r o c e s s p a r a m e t e r s e x i s t a t

t h e u n t e s t e d b a t t e r y . Such e m i s s i o n f a c t o r s s h o u l d , h o w e v e r ,

be r e f i n e d a s more d a t a a r e a c q u i r e d .

Why were so many c o r r e l a t i o n s a t t e m p t e d ?

T h i s s t u d y w a s , i n some w a y s , a p r o t o t y p e f o r s u b s e q u e n t

s t u d i e s . T h e r e f o r e , i t was i m p o r t a n t t o l e a r n t h e r e l a -

t i o n s h i p s , i f a n y , b e t w e e n p r o c e s s and e m i s s i o n v a r i a b l e s

t h a t c o u l d d e s c r i b e v a r i a t i o n s i n e m i s s i o n r a t e s .

Were a n y e s p e c i a l l y good c o r r e l a t i o n s d e v e l o p e d a s a r e s u l t

o f t h i s s t u d y ?

Yes. Net c o k i n g t i m e a p p e a r s t o be one of t h e mos t s i g n i f i -

c a n t v a r i a b l e s a f f e c t i n g a t l e a s t t h e o p a c i t y and d e g r e e

o f g r e e n n e s s ( s e e F i g u r e 5.7.4-1 and 5.7.4-2) and p r o b a b l y

t h e mass r a t e o f p a r t i c u l a t e e m i s s i o n s , a l t h o u g h d a t a

a n a l y s i s d i d n o t r e v e a l a n y s i g n i f i c a n t c o r r e l a t i o n s be-

tween e m i s s i o n f a c t o r and n e t c o k i n g t i m e . T h i s may a l s o be

t r u e f o r o t h e r c o n t a m i n a n t s . However, no d a t a were a c q u i r e d

t o s u b s t a n t i a t e t h e l a t t e r p o s t u l a t i o n . O b v i o u s l y , o t h e r

p r o c e s s c o n d i t i o n s m u s t be m a i n t a i n e d r e l a t i v e l y c o n s t a n t

f o r any of t h e s e c o r r e l a t i o n s t o be d e v e l o p e d a n d , i n f a c t ,

t h e y were r e l a t i v e l y c o n s t a n t d u r i n g t h e Burns H a r b o r s a m p l i n g .

U n f o r t u n a t e l y , t h e s m a l l number o f p a r t i c u l a t e s a m p l e s

p r e c l u d e d t h e p o s s i b l e d e v e l o p m e n t o f a s t a t i s t i c a l

r e l a t i o n s h i p b e t w e e n p a r t i c u l a t e e m i s s i o n s and o t h e r

v a r a m e t e r s .

a . Q.

A .

9 . Q .

A .

1 0 . Q .

A .

11. Q.

A .

12. Q.

A .

13 . Q .

A .

- 121 - Who o b t a i n e d t h e p r o c e s s i n f o r m a t i o n f o r t h i s s t u d y ?

Be th lehem S t e e l C o r p o r a t i o n p e r s o n n e l g a t h e r e d t h e i n f o r -

m a t i o n wh ich was t h e n p r o v i d e d e i t h e r d i r e c t l y t o U . S .

EPA p e r s o n n e l o r t o C l a y t o n p e r s o n n e l .

.f

Who o b t a i n e d t h e s a m p l i n g a n d a n a l y t i c a l d a t a ?

C l a y t o n p e r s o n n e l ( s e e A p p e n d i x R R , Volume 6 ) .

Who o b t a i n e d t h e v i s i b l e e m i s s i o n s d a t a ?

U.S. EPA p e r s o n n e l ( s e e A p p e n d i x R R , Volume 6 ) .

Were t h e r e a n y e x p e r i m e n t a l ( a t y p i c a l ) oven d o o r s , u n u s u a l

m a i n t e n a n c e , o r o t h e r p e c u l i a r o p e r a t i n g c o n d i t i o n s d u r i n g

t h e t e s t s ?

Yes . E x p e r i m e n t a l d o o r s w e r e o b s e r v e d i n u s e on a few of

t h e coke o v e n s . No u n u s u a l o r a b n o r m a l m a i n t e n a n c e or

o p e r a t i n g c o n d i t i o n s w e r e n o t e d on a n y o f t h e d a t a p r o -

v i d e d t o C l a y t o n p e r s o n n e l .

Did a n a n a l y s i s o f B e t h l e h e m S t e e l C o r p o r a t i o n p o l l u t i o n

a n d / o r i n s p e c t i o n r e p o r t s document t h a t t h e p l a n t , or a t

l e a s t t h e oven d o o r s , w e r e b e i n g h a n d l e d a n d / o r m a i n t a i n e d

i n a n u n u s u a l f a s h i o n i m m e d i a t e l y b e f o r e or d u r i n g t h e

t e s t p e r i o d a s compared t o o t h e r p e r i o d s ?

No. However, i n s p e c t i o n r e p o r t s a r e t o o i n f r e q u e n t t o d e f i n e . t h e s e c o n d i t i o n s v e r y e f f e c t i v e l y ( s e e Append ix YY, Volume 7 ) . '

-

9:

. What i s t h e optimum n e t c o k i n g t i m e f o r r e d u c t i o n o f emis -

s i o n s ?

W i t h o u t a n a n a l y s i s o f t h e minimum n e t c o k i n g t i m e n e c e s -

s a r y for p r e v e n t i n g coke -oven " s t i c k e r s ," t h i s a n s w e r c a n -

n o t be p r o v i d e d .

- 1 2 2 - 1 4 . Q. What is t h e b e s t method o f d e s c r i b i n g " g r e e n n e s s " i n a

q u a n t i f i e d s e n s e ?

A. The p r o d u c t of t h e B u m of t h e greennee8 r a t i n g 8 a n d t h e

d u r a t i o n o f t h e push waa j u d g e d t o be t h e b e s t . , %

9) 1 5 . Q . Is t h e r e a n y s p e c i f i c r e a s o n f o r v e r y g r e e n p u s h e s ? n

A . T h i s c o u l d n o t be d e t e r m i n e d w i t h a n y d e g r e e o f c e r t a i n t y .l

s i m p l y b e c a u s e t h e r e w e r e n ' t enough " v e r y g r e e n pushes ' ' t o

a c q u i r e s t a t i s t i c a l i n f o r m a t i o n . Only a f e w v e r y g r e e n

p u s h e s were o b s e r v e d d u r i n g t h e s o u r c e t e s t i n g . However,

a s m e n t i o n e d p r e v i o u s l y , t h e s h o r t e r t h e n e t c o k i n g t i m e ,

a p p a r e n t l y t h e g r e a t e r t h e d e g r e e of g r e e n n e s s and t h e

h i g h e r t h e o p a c i t y of e x h a u s t d u c t e m i s s i o n s . An e s p e c i a l l y

" c o l d " o v e n , o p e r a t i n g s i g n i f i c a n t l y be low t h e a v e r a g e c r o s s -

w a l l t e m p e r a t u r e o f t h e o t h e r o v e n s , c o u l d v e r y l i k e l y c a u s e

a v e r y g r e e n p u s h .

7

$J ., t'

c

1 6 . Q . Could t h e c a u s e s o f l e a k s from t h e coke -oven shed be q u a n t i -

f i e d s u f f k i e n t l y t o i n d i c a t e wh ich v a r i a b l e was mos t s i g -

n i f i c a n t r e g a r d i n g f u g i t i v e p a r t i c u l a t e e m i s s i o n s ?

A . No. Too many i n d e p e n d e n t v a r i a b l e s were w o r k i n g t o g e t h e r

t o a f f e c t l e a k a g e f rom t h e s h e d . These i n c l u d e d w i n d ,

e x h a u s t g a s f l o w r a t e t h r o u g h t h e s h e d s y s t e m , l o c a t i o n o f

t h e oven p u s h e d , g r e e n n e s s o f a s p e c i f i c p u s h , e t c .

17 . Q. Why was a t h r e e - m i n u t e peak s a m p l i n g p e r i o d c h o s e n i n s t e a d

o f a 2 -1 /2 -minu te peak p e r i o d ?

A . The t h r e e t y p e s o f d a t a a c q u i r e d t o o b t a i n a n a c c u r a t e e s t i -

m a t e o f t h e maximum p e r i o d o f p u s h i n g e m i s s i o n s e v a c u a t i o n

from t h e s h e d ( t e m p e r a t u r e , f i l t e r o b s c u r i t y , and o p a c i t y )

- 123 - a l l i n d i c a t e d t h a t t h e b e s t m e a s u r e of peak p u s h i n g emis-

s i o n s was one t a k e n o v e r a t h r e e - m i n u t e i n t e r v a l . I n f a c t ,

t h e p r e l i m i n a r y p r o c e d u r e s t o i n d i c a t e and q u a n t i f y t h i s

p e a k p u s h i n g e m i s s i o n s e v a c u a t i o n p e r i o d were p e r f o r m e d

n o t o n l y p r i o r t o b e g i n n i n g e m i s s i o n t e s t i n g , b u t e v e n 3

j

d u r i n g t h e p r e l i m i n a r y t e s t s on F e b r u a r y 24, 1975 so t h a t i

t h e b e s t i n d i c a t o r s p o s s i b l e o f t h a t s u b j e c t p e r i o d would

b e o b t a i n e d . I t t u r n e d o u t t h a t t h e c h o i c e o f t h r e e m i n u t e s

was v e r y p r o p i t i o u s , e s p e c i a l l y when t h e d a t a were e v a l u a t e d

a f t e r t h e s o u r c e t e s t i n g was p e r f o r m e d . The o p a c i t y d a t a

i n d i c a t e d s t r o n g l y t h a t t h e c h o i c e o f t h r e e m i n u t e s was

n o t o n l y f o r t u n a t e b u t v e r y a c c u r a t e a s w e l l ( s e e F i g u r e s

5.7.5-2 a n d 5.7.5-3).

18. Q. Why was t h e p r o b e r o t a t e d i n t h e s t a c k r a t h e r t h a n b e i n g

p u l l e d o u t b e t w e e n s a m p l i n g p o i n t s ( f o r t h e peak e m i s s i o n

t e s t s ) ?

A . The i n s e r t i o n a n d w i t h d r a w a l o f t h e , p robe would more l i k e l y

c a u s e s a m p l i n g e r r o r and p o s s i b l e sample l o s s e s . A d d i t i o n a l l y ,

i t w a s i m p o r t a n t t o r o t a t e t h e f a c e o f t h e n o z z l e away f rom

t h e e n t e r i n g s t r e a m l i n e s o f t h e e x h a u s t g a s f l o w d u r i n g

n o n - s a m p l i n g p e r i o d s . T h e r e f o r e , t h e f a c e of t h e n o z z l e 1)

was r o t a t e d w i t h t h e p r o b e a t l e a s t 9 0 " o f f o f f a c i n g d i r e c t l y ,

i n t o t h e e x h a u s t g a s f l o w wheneve r t h e s a m p l i n g t r a i n was

s h u t down. 9

1 9 . Q. Why w a s n ' t t h e a t t e n u a t i o n c o e f f i c i e n t a good i n d i c a t o r o f

t h e p a r t i c u l a t e c o n c e n t r a t i o n i n t h e d u c t ?

n c'

i.

7

- 1 2 4 - A . The c l o s e n e s s o f t h e m e a s u r e d p a r t i c u l a t e c o n c e n t r a t i o n s

among t h e t h r e e s a m p l e r u n s p r e c l u d e d t h e a b i l i t y t o

d i s t i n g u i s h be tween a v e r a g e a t t e n u a t i o n c o e f f i c i e n t s f o r

t h e c o n t i n u o u s p a r t i c u l a t e e m i s s i o n t e s t s . T h u s , t h e

a t t e n u a t i o n c o e f f i c i e n t may h a v e b e e n a good i n d i c a t o r o f

p a r t i c u l a t e c o n c e n t r a t i o n b u t c o u l d n o t b e c o r r e l a t e d w i t h

s u c h a n a r r o w r a n g e o f a v e r a g e p a r t i c u l a t e e m i s s i o n con-

c e n t r a t i o n s .

2 0 . Q. Was t h e p r o p e r p a t h l e n g t h u t i l i z e d f o r a t t e n u a t i o n c o e f f i -

c i e n t c a l c u l a t i o n s ?

A . Yes . M r . K i r k F o s t e r o f t h e U.S. EPA h e l p e d i n t h i s en -

d e a v o r .

2 1 . Q . Why were t h e p r o b e and f i l t e r m a i n t a i n e d s t t h e t e m p e r a t u r e

of t h e s t a c k ?

A . Because i t w a s p a r t o f t h e o b j e c t i v e t o n e i t h e r c r e a t e n o r

d i m i n i s h f i l t e r a b l e p a r t i c u l a t e m a t t e r .

2 2 . Q. How f r e q u e n t l y was t h e A p c h e c k e d f o r i s o k i n e t i c s a m p l i n g ?

A . It was m o n i t o r e d c o n t i n u o u s l y . F o r peak s a m p l i n g , i t was

r e c o r d e d e v e r y 30 s e c o n d s ( s e e Appendix LL, Volume 5).

23. Q . Why was a c e t o n e used r a t h e r t h a n some o t h e r o r g a n i c s o l v e n t

f o r c l e a n i n g up t h e s a m p l i n g t r a i n ?

A . Not o n l y is i t t h e recommended p r o c e d u r e i n U.S. EPA Method

5 , b u t a c e t o n e e f f e c t i v e l y removes t h e d e p o s i t i o n o f p a r t i c u -

l a t e m a t t e r and a l l o w s f o r good c l e a n - u p o f t h e componen t s

o f t h e s a m p l i n g t r a i n when s a m p l i n g coke -oven e m i s s i o n s .

24. Q.

A.

25. Q.

A.

26. Q.

A.

- 1 2 5 -

Shou ld c y c l o h e x a n e b e u s e d a s t h e s o l v e n t f o r s a m p l i n g

t r a i n c l e a n - u p f o r c o k e - o v e n p a r t i c u l a t e t e s t s i n t h e

f u t u r e ?

The r e s u l t s o f s a m p l i n g f o r c y c l o h e x a n e s o l u b l e s and i n s o l u -

b l e s p r e s e n t e d i n S e c t i o n 5 . 5 i n d i c a t e t h a t c y c l o h e x a n e may

b e a p r e f e r a b l e s o l v e n t . A c e t o n e was u s e d i n t h i s s t u d y ,

however , b e c a u s e i t i s r e q u i r e d by t h e s t a n d a r d EPA Method

5 p r o c e d u r e . I n a c t u a l i t y a c e t o n e may be a b e t t e r s o l v e n t

b e c a u s e i t i s a b e t t e r w e t t i n g a g e n t t h a n c y c l o h e x a n e , i . e . ,

removes p a r t i c u l a t e m a t t e r by w e t t i n g r a t h e r t h a n s o l u b i l i t y .

How d i d we a t t e m p t t o q u a n t i f y t h e o r g a n i c f r a c t i o n o f t h e

p a r t i c u l a t e m a t e r i a l ?

Through t h e u s e o f a c e t o n e s o l u b i l i t y , t h e c y c l o h e x a n e c a p -

t u r e t e c h n i q u e , t h e a c t i v a t e d c a r b o n a d s o r p t i o n t e c h n i q u e ,

and g r a b f l a s k s a m p l e s ( s e e Appendix LL, Volume 5 ) .

How d i d w e a c c o u n t f o r o r a v o i d p o t e n t i a l s a m p l i n g and

a n a l y t i c a l p r o b l e m s w i t h s u l f a t e , n i t r i t e , n i t r a t e , h y d r o -

g e n c h l o r i d e s , and p s e u d o - p a r t i c u l a t e ?

By m a i n t a i n i n g t h e s a m p l i n g c o n d i t i o n s v e r y c l o s e t o t h e

s t a c k c o n d i t i o n s e x t a n t d u r i n g t h e t y p e o f t e s t s ( w h e t h e r

c o n t i n u o u s o r p e a k ) , and w i t h p r e - p l a n n i n g r e g a r d i n g t h e

a n a l y t i c a l t e c h n i q u e s u s e d . T h e s e t e c h n i q u e s m i n i m i z e d

p o t e n t i a l p r o b l e m s w i t h p s e u d o - p a r t i c u l a t e g e n e r a t i o n i n

t h e i m p i n g e r s . The e x t e n t t o which t h e a f o r e m e n t i o n e d

s p e c i e s a f f e c t e d r e s u l t s i s m i n i m a l s i n c e p a r t i c u l a t e

a n a l y s e s r e v e a l s m a l l amoun t s o f t h e s e m a t e r i a l s ( s e e

T a b l e s 5 .3-2 and 5.5).

1

x, .l

- 1 2 6 - 27. Q. Do w e h a v e a t r u e r e p r e s e n t a t i o n o f t h e t e s t p e r i o d com-

p a r e d t o t h e t y p i c a l p r o c e s s a t B a t t e r y 1 o f t h e Burns

Harbor p l a n t ?

A . Yes ( s e e S e c t i o n 3.2).

28. Q. How w e l l do o u r p a r t i c l e s i z e r e s u l t s r e p r e s e n t t h e EPA

Method 5 f i l t e r a b l e p a r t i c u l a t e c a t c h ?

A . Very w e l l ( see S e c t i o n 5 . 4 f o r c o m p l e t e d e t a i l s ) .

29. Q. Why were t h e peak and c o n t i n u o u s p a r t i c u l a t e e m i s s i o n r a t e s

d i f f e r e n t f o r e a c h t e s t ?

A . Because o f v a r i a b i l i t y o f i n d i v i d u a l coke-oven p u s h e s

and d o o r l e a k s ( s e e T a b l e s 5.6.1-1 t h r o u g h 5 . 6 . 1 - 6 ) .

30. Q. Why was t h e a v e r a g e " p u s h e s p e r h o u r " f i g u r e f o r t h e con-

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

t y p i c a l c o n d i t i o n ?

A . Because s a m p l i n g had t o b e i n t e r r u p t e d a t numerous t imes

f o r p r o c e s s m a l f u n c t i o n s a n d / o r f o r c h a n g i n g t h e 'probe

f rom p o r t t o p o r t . A d d i t i o n a l l y , t h e p r o c e d u r e ( s t o p p i n g

the s a m p l i n g wheneve r t h e p u s h - t o - p u s h t i m e e x c e e d e d 30

m i n u t e s ) s l i g h t l y i n c r e a s e d t h e p u s h e s p e r h o u r f i g u r e .

N e v e r t h e l e s s , i t was s t i l l w i t h i n t h e - + 10% c r i t e r i a ( s e e

T a b l e 3 .2 .2-1) . F u r t h e r , e v e n though t h i s w a s t h e c a s e ,

n o a p p a r e n t change i n t h e e m i s s i o n s d a t a o c c u r r e d be tween

t h e f i r s t c o n t i n u o u s p a r t i c u l a t e s ample r u n w h i c h o p e r a t e d

a t a r a t e of a b o u t 5 .2 p u s h e s p e r h o u r and t h e second and

t h i r d t e s t s w h i c h e a c h o p e r a t e d a t a r a t e o f a b o u t 4 . 8

p u s h e s p e r h o u r . A p p a r e n t l y , t h e n , t h e push -pe r -houb

3 1 . Q.

A .

3 2 . Q .

A .

3 3 . Q .

A .

3 4 . Q .

A .

3 5 . Q .

A .

3 6 . Q .

A .

- 127 - f i g u r e , wh ich o b v i o u s l y r e l a t e d t o t h e t o n s of coke c h a r g e d

p e r h o u r f o r e a c h s a m p l i n g p e r i o d , i s n o t a s i g n i f i c a n t c r i -

t e r i o n f o r e s t a b l i s h i n g a n a v e r a g e c o n t i n u o u s p a r t i c u l a t e

e m i s s i o n r a t e f rom t h e c o k e b a t t e r y .

What w a s t h e s t a b i l i t y o f p e r c e n t a g e o f d o o r l e a k a g e ,

w h e t h e r p u s h - s i d e oven d o o r , c o k e - s i d e oven d o o r , o r push -

s i d e chuck d o o r ?

Wide ly v a r i a b l e ( s e e T a b l e 5 . 6 . 3 ) .

Can we e s t i m a t e from d o o r l e a k a g e i n s p e c t i o n s how l o n g i t

t a k e s f o r a d o o r t o s t o p l e a k i n g ?

T h e r e a r e i n s u f f i c i e n t d a t a t o make t h i s e s t i m a t e f rom

t h e d a t a a c q u i r e d a t Burns H a r b o r ( s e e Append ix Y Y , Volume

7 ) .

What was t h e s t a b i l i t y o f n e t c o k i n g t i m e f o r t h e i n d i v i d u a l

coke-oven p u s h e s ?

Wide ly v a r i a b l e ( s e e A p p e n d i x 22, Volume 7 ) .

What w a s t h e s t a b i l i t y o f g r e e n n e s s by oven d a y - t o - d a y ?

Q u i t e u n s t a b l e e x c e p t i n t h e c a s e o f a few s e t s of ovens

wh ich a p p a r e n t l y were r e s p o n s i b l e f o r s l i g h t l y g r e e n e r

p u s h e s ( s e e Append ix 22, Volume 7 ) .

What was t h e s t a b i l i t y of t h e p e r c e n t a g e of m o i s t u r e o f

t h e c o a l m i x ?

Q u i t e s t a b l e ( s e e Appendix D , Volume 2 ) .

Who b u i l t B a t t e r y No. l ?

W i l p u t t e .

- 128 - 37. Q.

A .

3 8 . Q.

A .

39. Q.

A .

40. Q.

A .

Who b u i l t B a t t e r y No. 2 1

Kopper s .

How e x t e n s i v e were c h a i n - o f - c u s t o d y p r o c e d u r e s ?

Very e x t e n s i v e . Someone f rom t h e C l a y t o n c rew was always

p r e s e n t w i t h t h e s a m p l e s o r t h e s a m p l e s were l o c k e d s e c u r e l y

i n s t o r a g e ( s e e Append ix NN, Volume 6 ) .

Do you have o t h e r m a j o r r ecommenda t ions f o r s u b s e q u e n t

coke-oven t e s t work?

Yes. I n c l u d e a c o m p l e t e i n d u s t r i a l h y g i e n e / o c c u p a t i o n a l

h e a l t h s u r v e y a t t h e same t i m e t h e e m i s s i o n t e s t i n g is

p e r f o r m e d od a s u b j e c t b a t t e r y ; a c q u i r e v i s i b l e e m i s s i o n s

d a t e c o n t i n u o u s l y d u r i n g e a c h p a r t i c u l a t e s ample r u n ; and

c o n t i n u o u s l y r e f i n e t h e r e q u i r e d r o s t e r o f m a t e r i a l s t o be

measu red . What r e s e r v a t i o n s d o you h a v e r e g a r d i n g t h i s s t u d y ?

1. We b e l i e v e t h e i n f o r m a t i o n a c q u i r e d h e r e , a l t h o u g h o f

e x c e l l e n t q u a l i t y , s h o u l d n o t be e x t r a p o l a t e d i n d i s -

c r i m i n a t e l y t o a l l coke o v e n s .

2 . It would have b e e n h e l p f u l t o s u b s t a n t i a t e ( w i t h

" o f f i c i a l " p r o c e s s i n f o r m a t i o n ) t h a t t h e p r e - s t u d y

a v e r a g e c o a l f e e d r a t e a n d t h e p r e - s t u d y coke p r o d u c t i o n

r a t e were e q u i v a l e n t t o t h o s e r e c o r d e d d u r i n g and a f t e r

t h e s t u d y ( s e e T a b l e 3.2.2-1).

TECHNICAL REPORT DATA (Plenrc read I,,unrcrio,,r on rhe rerem before complerinr)

2. 3. R E C I P I E N T ' S ACCESSIONNO. I . REPORT NO. 34011-76-012

1. TITLE A N D S U B T I T L E 5. R E P O R T DATE 5-20-77

s o u r c e T e s t i n g o f a S t a t i o n a r y Coke-Side 6. P E R F O R M I N G ORGANIZATION CODE E n c l o s u r e

8. P E R F O R M I N G ORGANIZATION REPORT NO 7 . AUTHORIS)

Thomas A. Loch, John E. M u t c h l e r R i c h a r d J. Powal s , J a n e t L. Vecch io

C l a y t o n E n v i r o n m e n t a l C o n s u l t a n t s , I n c . 25711 S o u t h f i e l d Road S o u t h f i e l d , M i c h i g a n 48075

U.S. E n v i r o n m e n t a l P r o t e c t i o n Agency

4 0 1 M S t r e e t , S.W. Washingkon, D . C . 20460

IO. PROGRAM E L E M E N T NO. 9. P E R F O R M I N G ORGANIZATION N A M E A N D ADDRESS

11. CONTRACTIGRANT NO.

68-02-1408; Task 1 0 . 13. TYPE OF REPORT A N 0 P E R 1 0 0 COVERED 12. SPONSORING AGENCY N A M E A N 0 ADDRESS

14: SPONSORING A G E N C Y CODE . - D i v i s i o n of S t a t i o n a r y S o u r c e Enf 0rceme.n t

15. S U P P L E M E N T A R Y NOTES Volumes 2 - 1 2 of t h i s r e p o r t a r e a p p e n d i c e s t h a t su p l e -

(See Eo. 1 2 ment Volume 1 and a r e a v a i l a b l e f rom t h e s p o n s o r i n g agency a b o v e

T h i s r e p o r t summar izes a n e m i s s i o n s t u d y t h a t documents t h e na- t u r e and e x t e n t o f p a r t i c u l a t e and g a s e o u s e m i s s i o n s t y p i c a l l y e m a n a t i n g from t h e coke s i d e o f Coke B a t t e r y No. 1 a t t h e Burns Harbor P l a n t o f Beth lehem S t e e l C o r p o r a t i o n , C h e s t e r t o n , I n d i a n a . The i n f o r m a t i o n was ob t a i n e d t o h e l p p r o v i d e a b a s i s f o r :

16. ABSTRACT

1. Development o f EPA p o l i c y on c o k e - s i d e coke b a t t e r y e m i s s i o n s and t h e i r c o n t r o l .

2 . Asses smen t of t h e a d e q u a c y o f S t a t e I m p l e m e n t a t i o n P l a n s (SIPS) t o a c h i e v e N a t i D n a 1 A i r Q u a l i t y S t a n d a r d s i n a r e a s p rox ima te . t o coke p l a n t s .

3. A s s e s s m e n t of t h e a d e q u a c y o f c o n t r o l d e v i c e s b e i n g p roposed for a b a t e m e n t o f c o k e - s i d e e m i s s i o n s .

The s o u r c e t e s t i n g i n c l u d e d measurement o f 48 d i f f e r e n t contamin a n t s , and t h e p r o j e c t r e s u l t e d i n s e v e r a l p r o c e s s - e m i s s i o n c o r r e l a t i o n s .

17. K E Y WORDS A N D 0

a. DESCRIPTORS

Coking A i r P o l l u t i o n Ope c i t y V i s u a l I n s p e c t i o n P a r t i c l e s P a r t i c l e S i z e D i s t r i b u t i o n

I ? . O ISTRISUTION S T A T E M E N T

U n l i m i t e d

€PA F w r n 2220.1 14-73)

J M E N T A N A L Y S I S

IOENTIFIERS/OPEN E N D E D T E R M S

New S o u r c e Pe r fo rm- a n c e S t a n d a r d s

E m i s s i o n T e s t i n g

Pe r fo rmance Te 3 t s

3. SECURITY CLASS (This Reporr)

I. S E C U R I T Y CLASS (This page) U n c l a s s i f i e d

U n c l a s s i f i e d

COSATI FicldiCroup

13B 14D

1. NO. OF PAGES

128 ( V o l . 1 ) 2. PRICE

C R I T E R I A FOR IPM SAMYLIN(:

DATA REVIEW (I’rc Liialnnry Itevicw)

Rev4 ewer /Or ):ani zii t i n n & 4 /A h&$ Date R r v l c w d

Report Reference

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U.S. DEPARTMENT OF COMMERCE National Technical Information Service

__ _- -. .

Source Testing of a Stationary Coke-Side Enclosure. Volume 1. Burns Harbor Plant Bethlehem Steel Corp., Chesterton, Ind.

\

Clayton Environmental Consultants, Inc, Southfield, Mich . .-

Prepored for

Environmental Protection Agency, Washington, D C Div of Stationary Sourct Enforcement 20 May 77

c _... ... . . . . ....-- I&

I. - .

I d T A B L E O F C O N T E N T S

VOLUME 1

GLOSSARY OF TERMS ......................................... v

L1,ST OF FIGURES ...................... ..................... Viii

LIST OF TABLES ............................................ ix

LIST OF APPENDICES ......................................... Xi

1.0 INTRODUCTION ........................................... 1

2 . 0 SUMMARY AND CONCLUSIONS ............................... 12

,

2.1 Coke-Side Particulate Emissions ................. 1 2

2.1.1 Overall continuous coke-side particulate

2.1.2 Continuous particulate emissions from the

2.1.3 Peak particulate emissions from the ex-

2.1.4 Fugitive particulate emissions from the

2.1.5 Particulatc emissions for pushing opera-

2.1.6 Particulate emissions for non-pushing

emissions ................................ 12

exhaust duct ............................. 13

haust duct ............................... 13

shed ..................................... 1 4

tions .................................... 1 4

operations ............................... 14

2 . 2 Shed Particulate Capture Efficiency ............. 15

2.2.1 Evaluation of shed capture efficiency .... 15 2.2.2 Possible causes of leakage ............... 15

2.3 Chemical Composition of Psrticulate Emissions ... 16

2.4 Particle Size Distribution ...................... 16

2 . 5 Emissions of Other Materials .................... 16

2.6 Dustfall Measurements ........................... 16

2.7 Indices of Visible Emissions .................... 17

2.7.1 Degree of greenness ...................... 17 2.7.2 Opacity .................................. 17

c

ii

1

2 . 7 . 3 P e r c e n t o f d o o r s l e a k i n g ................ 2 . 8 P r o c e s s and E m i s s i o n s C o r r e l a t i o n s ............. 2.9 R e p r e s e n t a t i v e n e s s of P r o c e s s and Shed

C o n d i t i o n s ....................,................ 3 . 0 PKOCESS DESCRIPTION A N D OPERATIONS .................,.

3 . 1 . P r o c e s s D e s c r i p t i o n ............................ 1 . 3 I { e p r e s e n t a t i v e n e s s o f P r o c e s s and Shed Con-

d i t i o n s ........................................ 3.2 .1 C r i t e r i a f o r compar i son ................. 3 . 2 . 2 C o n d i t i o n s d u r i n g s a m p l i n g p e r i o d s ......

3 , 3 I d e n t i f i c a t i o n of P o s s i b l e N o r m a l i z i n g F a c t o r s . .

4 . 0 S A M P L I N G A N D A N A L Y T I C A L METHODS ...................... !I . I 4 , 2

4 . 3

4 . 4

4 . 5

4 . 6

/I - 7

4 . a h . 9

! ! I '

4 . 1 0

4 . 1 1

h

Page

1 8

1 8

19

2 0

20

2 5

2 5 28

3 2

3 3

T e s t P r o t o c o l .............................._.... 33

~ o c a t i o n of Sampl ing P o i n t s .................... 3 4

C o n t i n u o u s P a r t i c u l a t e E m i s s i o n s from Shed E x h a u s t Duct ................................... 3 5

D e t e r m i n a t i o n of Peak P a r t i c u l a t e E m i s s i o n P e r i o d 3 9

Peak P a r t i c u l a t e E m i s s i o n s from Shed E x h a u s t Duct 4 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 . . . . . . ................ 4 3

E m i s s i o n s o f O t h e r M a t e r i a l s ................... $4

i i u s t f a l l Measurements .......................... 4 5

S u b j e c t i v e and V i s u a l E m i s s i o n P a r a m e t e r s ...... 46

4.9 .1 . Degree of g r e e n n e s s ..................... 46 4 . 9 . 2 O p a c i t y o f shed e x h a u s t ................. 4 7 h - 9 . 3 P e r c e n t of d o o r s l e n k i n g ................. 1+? 4 . Y . 4 V i s u a l e s t i m a t e s o f f u g i t i v e e m i s s i o n s . . . 4 8

F v g i t i v e P a r t i c u l a t e E m i s s i o n s From t h e Shed ... 4 8

C a l i b r a t i o n s , Q u a l i t y A s s u r a n c e , and Sampl ing I n t e g r i t y ....................................... 4 9 \

i i i

.Q.E 5.0 PRESENTATION A N D DISCUSSION OF RESULTS ............... 5 1

5.1

5.2

5.3

5.4

5.5

5.6

5.7

5 .8

Coke-Side P a r t i c u l a t e E m i s s i o n s ................. 5 1

5.1.1 C o n t i n u o u s p a r t i c u l a t e e m i s s i o n s f rom t h e e x h a u s t d u c t ............................. 5 1

5.1.2 F u g i t i v e p a r t i c u l a t e e m i s s i o n s ........... 53 5.1.3 O v e r a l l c o n t i n u o u s c o k e - s i d e p a r t i c u l a t e

e m i s s i o n s ................................ 54 5.1.4 Peak p a r t i c u l a t e e m i s s i o n s f rom t h e shed . 56 5.1.5 P a r t i c u l a t e e m i s s i o n s f o r p u s h i n g o p e r a -

t i o n s .................................... 59 5.1.6 P a r t i c u l a t e e m i s s i o n s for non-push ing

o p e r a t i o n s ............................... 6 2

P a r t i c u l a t e C a p t u r e E f f i c i e n c y o f t h e Shed ...... 6 5

5.2.1 E v a l u a t i o n o f shed c a p t u r e e f f i c i e n c y .... 6 5 5.2.2 P o s s i b l e c a u s e s o f l e a k a g e ............... 6 5

Chemical Compos i t ion o f P a r t i c u l a t e E m i s s i o n s ... 6 9

P a r t i c l e S i z e D i s t r i b u t i o n ...................... 6 9

E m i s s i o n s o f O t h e r M a t e r i a l s .................... 7 7

I n d i c e s o f V i s i b l e E m i s s i o n s .................... 8 0

5.6.1 Degree o f g r e e n n e s s ...................... 80 5.6.2 O p a c i t y .................................. 8 8

5.6.2.1 E m i s s i o n s f rom e x h a u s t d u c t ..... 8 8 5.6.2.2 F u g i t i v e e m i s s i o n s .............. 8 9

5 . 6 . 3 , P e r c e n t o f d o o r s l e a k i n g ................. 9 0

E m i s s i .. n.Related C o r r e l a t i o n s ................... 92

5.7.1 C o r r e l a t i o n s b e t w e e n e m i s s i o n f a c t o r s and

5.7.2 C o r r e l a t i o n s be tween e m i s s i o n f a c t o r s and

5.7.3 C o r r e l a t i o n s i n v o l v i n g p a r t i c l e s i z e

5.7.4 C o r r e l a t i o n s be tween i n d i c e s o f v i s i b l e

5.7.5 C o r r e l a t i o n s among v i s i b l e e m i s s i o n s

i n d i c e o o f v i s i b l e e m i s s i o n s ............. 92

p r o c e s s c o n d i t i o n s ....................... 93

d i s t r i b u t i o n s ............................ 94

e m i s s i o n s and p r o c e s s c o n d i t i o n s ......... 94

measu remen t s .............................. 101

E f f e c t o f t h e Shed Upon D u s t f a l l ................ 103

. 340/1-76-012 U.S. EPA, Division of S ta t ion- I

ary Source Enforcement Source Test ing of A - - - Sta t ionary Coke -S i d e Enclosure

May 1977 _ _ _._- -

---1 - = . , ,

, A ' /

....

- ---I--- -t .

i . ! '3

. .

C z

II S t a c k C o n d i t i o n s

L A v e r a g e

P r o c e s s W e i g h t R a t e

P a r t i c u l a t e P a r t i c u l a t e C o n c e n t r a t i o n Emission R a t e

(gr /LISCF)* ( l b s / h r ) *

B u r n s H a r b o r P l a n t B e t h l e h e m S t e e l C o r p o r a t i o n

C h e s t e r t o n , l n d l a n a March 3-7, 1975

I F l l t e r a b l r :

l b s / t o n l b s / t o n d r y c o a l c o k e +

0.76 0.97

0.79 1.0

0.78 0.99

0.78 0.99

T o t a l

l b s / t o n l b s / t o n 1

d r y c o a l c o k e +

0.79 1.0

0.81 1.0

0.81 1.0

0 . 8 0 1.0

Temp (OF)

84

94

98

92

'I F l o u r a t e F i l t e r - T o t u l F i l t e r - t o n s wet t o n s d r ]

( D S C F H ) a b l e a b l e c o a l / h r c o a 1 / 1 1 r

269,000 0.056 0 . 0 5 8 129 134 1 8 3 170

268,000 0 . 0 5 4 0.055 123 127 16 7 156

266,000 0.053 0.056 1 2 1 127 16 8 156

268,000 0.054 0.056 124 129 173 16 1 . * These v a l u e s do n o t i n c l u d e f u g i t i v e p a r t i c u l a t e e m i s s i o n s ( s ee T a b l e 5 . 1 . 3 f o r o v e r a l l e m l s s i

+ B e t h l e h e m S t e e l C o r p o r a t i o n h a e i n d i c a t e d t h a t 0 . 7 3 t o n of c o k e is p r o d u c e d p c r ton o f I1 wet c o a l c h a r g e d .

SUMMAKY Ol” OVERALL CONTINUOUS PARTICULATE EMISSIONS FROM THE S H E D

C o n t i n u o u s P a r t f c u l e t e

T e s t No.

1

2

3

Aver a g e -

B u r n s H a r b o r P l a n t H e t l i l e h e m S t e e l C o r p o r a t i o n

C h e s t e r t o n , I n d f a n a March 3-7, 1975

O v e r a l l C o n t i n u o u s Fi 1 t e r a b l e P a r t i c u l a t e

E m i s s i o n s E s t i m a t e

C o n t i n u o u s Fi l t e r a l l e E s t i m a t e d F u g i t i v e P a r t i c u l a t e E m i s s i o n s P a r t i c u l a t e E m f s s i o n s

E m i s s i o n E m i e a i o n Emf 8 8 i o n E m i s s i o n F a c t o r Emission F a c t o r E m i s s i o n F a c t o r

( l b s l h r ) l b s l t o n l b s l t o n ( l b a / l i r ) l b s l t o n l t s / t o n ( l b s l l l r ) l b s l t o n l b s / t o n R a t e R a t e R a t e

dry c o a l c o k e d r y c o a l c o k e d r y c o a l c o k e

129 0.76 0.97 21.9 0.13 0.17 1 5 1 0.89 1.1

123 0.79 1 . 0 21.9 0.14 0.18 145 0.93 1.2

121 0.78 0.99 21.9 0.14 0.17 1 4 3 0.92 1.2

124 0.78 0.99 21.9 0.14 0.17 146 0.91 1.2 I

Average

B u r n s H a r b o r P l a n t B e t 11 l e h e m S K e e 1 Co r p o r a t io n

C h e s t e r t o n , I nd i a n a March 3 - 7 , 1 9 7 5

I

P a r t i c u l a t e P a r t i c u l a t e W e i g h t R a t e + I ( g r / D S C F ) * (1 bs /hr )+

S t a c k G a s C o n d i t i o n s C o n c e n t r a t i o n E m i s e i o n H a t e

1 1 3

1 2 8

1 3 1

1 2 4

I I

158 1 4 7

116 1 5 7 1 4 6

1 5 7 1 4 6

2 5 7 , 0 0 0 0 . 1 4 8 0 . 1 6 2 7 3 . 4 80.5

2 6 2 , 0 0 0 0 . 2 2 1 0 . 2 3 0 1 1 2

2 5 1 , 0 0 0 0 . 1 9 5 0 . 2 1 9 9 4 . 2 106

1 4 6

P a r t i c u l a t e E m i s s i o n F a c t o r +

F i l t e r a b l e i T o t a l

l b s / t o n Iry c o a :

0 . 5 0

0 . 7 7

0 . 6 5

-

0 . 6 4

0 . 8 2 0 . 7 3

o .e i 1 0 .69

* T h e s e v a l u e s d o n o t i n c l u d e f u g i t i v e p a r t i c u l a t e e m i a s i o n a .

.t Erni .es lon r a t e s a n d ~ K O C ~ S Y w e i g h t r a t e s assume t y p i . c a 1 o p e r a t l o n a ; i . e . , 4.5 p u a h e a / h o u r *

b a / t o n c o k e f

I

TABLE 5 . 1 . 6

CALCULATION OF F I L T E R A B L E P A R T I C U L A T E E M I S S I O N FACTOR FOR N O N - P U S I I I N G O P E R A T I O N S

B u r n 8 H a r b o r P l a n t B e t h l e h e m S t e e l C o r p o r a t i o n

C h e e t e r t o n , I n d i a n a Merch 3 - 7 , 1 9 7 5

P a r t i c u l a t e

T A B L E 5 . 3 - 1

SUMMARY OF METALS A N D SULFATE CONTtiNT OF PARTICULATE SAMPLES

B u r n s Harbor P l a n t B e t h l e h e m S t e e l C o r p o r a t i o n

C h e s t e r t o n , I n d i a n a

S a m p l i n g C o n d i t i o n s

C o n t i n u o u s I

P e a k I 1 r e s t $ 0 . - 1

2

3

1

2

3

-

P o r t i o n o f

i a r n p l i n g T r a i n - F r o n t T o t a l

F r o n t T o t a l

F r o n t Tocel

f r o n t T o t a l

F r o n t T o t a l

P f o n t T o t a l

I__

M a r c h 3-7, 1975

Ca - 0.01 0.02

0 . 0 3 0.04

0.02 0 . 0 3

0.03 0 . 0 6

0 . 0 1 0 . 0 2

0.00: 0 . 0 2

m

I

;f 0.00 0.00:

P e r c e n t of P a r t i c u l a t e U e i a h t

-

T i a_

0 . 1 0.09

0 . 0 4 0 . 0 4

0.04 0.03

- s 0; .13c.

2 . 8 4 . 5

3 . 3 4.2

4 . 1 4 . 5

3.1 4.4

L . :i ;. !

..

i

SOURCE TESTING OF A STATIONARY C O K E - S I D E ENCLOSURE

(Volume 1 o f 1 2 )

Burns H a r b o r P l a n t Beth lehem S t e e l C o r p o r a t i o n

C h e a t e r t o n , I n d i a n a

C o n t r a c t No. 68-02-1408 Task No. 1 0

P r e p a r e d f o r :

D i v i s i o n o f S t a t i o n a r y S o u r c e E n f o r c e m e n t T e c h n i c a l S u p p o r t Branch

U.S. E n v i r o n m e n t a l P r o t e c t i o n Agency Wash ing ton , D . C . 20460

P r o j e c t O f f i c e r :

Louis R. P a l e y , P.E.

May 2 0 , 1977

P r e p a r e d b y :

C l a y t o n E n v i r o n m e n t a l C o n s u l t a n t s , I n c . 25711 S o u t h f i e l d Road

S o u t h f i e l d , M i c h i g a n 48075

T A B L E O F C O N T E N T S

Page VOLUME 1 -- GLOSSARY OF TERMS ......................................... V

LIST OF FIGURES ........................................... Viii

LIST OF TABLES ............................................ ix

LIST OF APPENDICES ........................................ Xi

1 1.0 INTRODUCTION ......................................... 2 . 0 SUMMARY AND CONCLUSIONS .............................. 1 2

2 . 1 Coke-Side Particulate Emissions ................. 1 2

2 . 1 . 1 Overall continuous coke-side particulate

2 . 1 . 2 Continuous particulate emissions from the

2 . 1 . 3 Peak particulate emissions from the ex-

2 . 1 . 4 Fugitive particulate emissions from the

2 . 1 . 5 Particulate emissions for pushing opera-

2 . 1 . 6 Particulate emissions for non-pushing

emissions ................................ 1 2

exhaust duct ............................. 13

haustduct............................... 13

shed ..................................... 1 4

tions .................................... 14

operations ............................... 1 4

2 . 2 Shed Particulate Capture Efficiency ............. 15

2 . 2 . 1 Evaluation of shed capture efficiency .... 15 2 . 2 . 2 Pos,sible causes of leakage ............... 15

2 . 3 Chemical Composition of Particulate Emissions ... 16

2 . 4 Particle Size Distribution ...................... 16

2 . 5 Emissions of Other Materials .................... 16

2 . 6 Dustfall Measurements ........................... 16

2 . 7 Indices of Visible Emissions .................... 1 7

2 . 7 . 1 Degree of greenness ...................... 1 7 2 . 7 . 2 Opacity .................................. 1 7

ii

.

2 . 7 . 3 P e r c e n t o f d o o r s l e a k i n g ................ 18

2 . 8 P r o c e s s and E m i s s i o n s C o r r e l a t i o n s ............. 18

2 . 9 R e p r e s e n t a t i v e n e s s of P r o c e s s and Shed C o n d i t i o n s ..................................... 19

3 . 0 PROCESS D E S C R I P T I O N AND OPERATIONS ................... 20

3.1 P r o c e s s D e s c r i p t i o n ............................ 20

3 . 2 R e p r e s e n t a t i v e n e s s o f P r o c e s s a n d Shed Con- d i t i o n s ........................................ 25

3 . 2 . 1 C r i t e r i a f o r c o m p a r i s o n ................. 25 3 . 2 . 2 C o n d i t i o n s d u r i n g s a m p l i n g p e r i o d s ...... 28

3 . 3 I d e n t i f i c a t i o n of P o s s i b l e N o r m a l i z i n g F a c t o r s .. 3 2

4 . 0 SAMPLING AND A N A L Y T I C A L METHODS ...................... 33

4 . 1 T e s t P r o t o c o l .................................. 3 3

4 . 2 L o c a t i o n o f S a m p l i n g P o i n t s .................... 34

4 . 3 C o n t i n u o u s P a r t i c u l a t e E m i s s i o n s from Shed E x h a u s t Duct ................................... 35

4 . 4 D e t e r m i n a t i o n of Peak P a r t i c u l a t e E m i s s i o n P e r i o d 3 9

4 . 5 Peak P a r t i c u l a t e E m i s s i o n s from Shed E x h a u s t Duct 4 3

4 . 6 P a r t i c l e S i z e D i s t r i b u t i o n ...................... 43

4 . 7 E m i s s i o n s o f O t h e r M a t e r i a l s ................... 4 4

4 . 8 D u s t f a l l Measuremen t s . . . . . . . . . . . . . . . . . . . . . . . . . . 45

4 . 9 S u b j e c t i v e and V i s u a l E m i s s i o n P a r a m e t e r s ...... 46

4 . 9 . 1 Degree of g r e e n n e s s ..................... 46 4 . 9 . 2 O p a c i t y o f shed e x h a u s t ................. 47 4 . 9 . 3 P e r c e n t o f d o o r s l e a k i n g ................. 47 4 . 9 . 4 V i s u a l e s t i m a t e s o f f u g i t i v e e m i s s i o n s ... 48

4 . 1 0 F u g i t i v e P a r t i c u l a t e E m i s s i o n s From t h e Shed ... 48

4 . 1 1 C a l i b r a t i o n s . Q u a l i t y A s s u r a n c e . and S a m p l i n g I n t e g r i t y ...................................... 49

?

.. -.c ..

......... . - d ...

iii

5.0 PRESENTATION AND DISCUSSION OF RESULTS ............... 5.1 Coke-S ide P a r t i c u l a t e E m i s s i o n s .................

5 . 1

5.1

5 . 2 P a r

5.1.1 C o n t i n u o u s p a r t i c u l a t e e m i s s i o n s f rom t h e e x h a u s t d u c t .............................

5.1.2 F u g i t i v e p a r t i c u l a t e e m i s s i o n s ........... 5.1.3 O v e r a l l c o n t i n u o u s c o k e - s i d e p a r t i c u l a t e

e m i s s i o n s ................................. 5.1.4 Peak p a r t i c u l a t e e m i s s i o n s f rom t h e s h e d .

t i o n s .................................... o p e r a t i o n s ...............................

5 P a r t i c u l a t e e m i s s i o n s f o r p u s h i n g o p e r a -

6 P a r t i c u l a t e e m i s s i o n s f o r n o n - p u s h i n g

i c u l a t e C a p t u r e E f f i c i e n c y of t h e Shed ...... 5.2.1 E v a l u a t i o n o f s h e d c a p t u r e e f f i c i e n c y .... 5.2.2 P o s s i b l e c a u s e s o f l e a k a g e ...............

5 .3 Chemica l C o m p o s i t i o n . o f P a r t i c u l a t e E m i s s i o n s ... 5.4 P a r t i c l e S i z e D i s t r i b u t i o n ...................... 5.5 E m i s s i o n s o f O t h e r M a t e r i a l s .................... 5.6 I n d i c e s o f V i s i b l e E m i s s i o n s ....................

5.6.1 Degree o f g r e e n n e s s ...................... 5.6.2 O p a c i t y ...................................

5.6.2.1 E m i s s i o n s f rom e x h a u s t d u c t ..... 5.6.2.2 F u g i t i v e e m i s s i o n s ..............

5.6.3 P e r c e n t o f d o o r s l e a k i n g ................. 5.7 E m i s s i o n - R e l a t e d C o r r e l a t i o n s ...................

5.7.1 C o r r e l a t i o n s b e t w e e n e m i s s i o n f a c t o r s and

5.7.2 C o r r e l a t i o n s b e t w e e n e m i s s i o n f a c t o r s and

5.7.3 C o r r e l a t i o n s i n v o l v i n g p a r t i c l e s i z e

5.7.4 C o r r e l a t i o n s b e t w e e n i n d i c e s o f v i s i b l e

5.7.5 C o r r e l a t i o n s among v i s i b l e e m i s s i o n s

i n d i c e s o f v i s i b l e e m i s s i o n s ............. p r o c e s s c o n d i t i o n s ....................... d i s t r i b u t i o n s ............................ e m i s s i o n s and p r o c e s s c o n d i t i o n s ......... m e a s u r e m e n t s .............................

Page .

. .

5.8 E f f e c t o f t h e Shed Upon D u s t f a l l ................. 1 0 3

51

5 1

5 1 5 3

54 56

59

6 2

6 5

6 5 6 5

6 9

6 9

7 7

a0

80 88

aa a 9

90

92

92

9 3

94

94

101

7 I_-

.. - .. 1

I i v

Page - 5 . 9 Impact o f t h e Shed Upon A i r b o r n e A g e n t s W i t h i n

t h e Shed ........................................ 115

5.10 P r e c i s i o n o f T e s t R e s u l t s ....................... 115

6.0 REFERENCES ........................................... 117

7 . 0 SOME ANTICIPATED QUESTIONS AND ANSWERS RELATED TO T H I S PROJECT .............................................. 118 -

VOLUME 2

Append ices A-E (See page x i f o r t i t l e s

VOLUME 3

Append ices F-H (See page x i f o r t i t l e s

VOLUME 4

Append ices 1-0 (See page x i f o r t i t l e s

VOLUME 5

Append ices P-MM (See p a g e s x i and x i i f o r t i t l e s )

VOLUME 6

Append ices NN-WW (See p a g e x i i i f o r t i t l e s )

VOLUME 7

Append ices XX-22 (See p a g e x i i i f o r t i t l e s )

VOLUME 8

Appendix. AAA (See page x i i i f o r t i t l e s )

VOLUME 9

Appendix BBB (See page x i i i f o r t i t l e s )

VOLUME 10

Appendix CC.C (See page x i i i f o r t i t l e s )

VOLUME 11

Appendix D D D (See page x i i i f o r t i t l e s )

VOLUME 1 2 I

Append ices E E E - G G G (See page x i v f o r t i t l e s )