# Information Collection Request Boiler MACT Emissions Report

We Energies Valley Power Plant Boiler 3 Outlet Duct Milwaukee, Wisconsin April 20 through 22, 20101520 Kensington Road, Suite 204 Oak Brook, IL 60523-2141 630-521-9400 630-521-9494 fax



# Information Collection Request Boiler MACT Emissions Report

We Energies Valley Power Plant Boiler 3 Outlet Duct Milwaukee, Wisconsin April 20 through 22, 2010

Report Submittal Date June 24, 2010

Prepared By

Platt Environmental Services
Report No. M101602

# Table of Contents

1.0 INTRODUCTION .............................................................................................................................. 1
2.0 EXECUTIVE SUMMARY ................................................................................................................. 2
3.0 TEST METHODOLOGY .................................................................................................................. 3 Method 1 Sample and Velocity Traverse Determination .............................................................3 Method 2 Volumetric Flow Rate Determination ...........................................................................3 Method 3A Oxygen (O2)/Carbon Dioxide (CO2) Determination ..................................................4 OTM27 Filterable Particulate Determination ................................................................................4 OTM 028 Condensable Particulate Determination ......................................................................4 Method 29 Trace Metals Determination .......................................................................................5 Mercury Determination by Method 30B (Sorbent Trap Method) ..................................................5
4.0 TEST RESULTS SUMMARIES ....................................................................................................... 6
5.0 CONCLUSION AND CERTIFICATION ......................................................................................... 10
APPENDIX Test Sectio n Diagrams.......................................................................................................... .....12 Sample Trai n Diagrams .......................................................................................................... ...14 Calculation Nomenclature and Fo rmulas...................................................................................20 Sample Anal ysis Data........................................................................................................... .....36 Reference Method Test Data (Computerized Sheet s)...............................................................75 Calibrati on Data ............................................................................................................... ........104 Gas Certificat ion S heets ....................................................................................................... ...139 Field Data Sheets.............................................................................................................. .......141ICR Boiler MACT Emissions R eport PES Report No.: M101602 We Energies-Valley Power Plant Boiler 3 Outlet Duct April 20 through 22, 2010



### 1 

# 1.0 Introduction

PLATT ENVIRONMENTAL SERVICES (PES) conducted an information collection request (ICR) boiler maximum achievable control technology (MACT) emissions test program for We Energies at the Valley Power Plant on the Boiler 3 Outlet Duct on April 20 through 22, 2010. This report summarizes the results of the test program and test methods used.

The test location, test dates, and test parameters are summarized below, in Table 1.



## Table 1
Test Overview

Test Location Test Dates Test Method Test Parameters
USEPA Method 3A Oxygen (O 2 ), Carbon Dioxide (CO 2 ) Other Test Method 27 (OTM27) <PM2.5 Filterable Particulate, Total Filterable Particulate Other Test Method 28 (OTM 28) Condensable Particulate

USEPA Method 5/29 Antimony (Sb), Arsenic (As), Beryllium (Be), Cadmium (Cd), Chromium (Cr), Cobalt (Co), Lead (Pb), Manganese (Mn), Nickel (Ni), Selenium (Se) and Filterable Particulate Boiler 3 Outlet Duct April 20 through 22, 2010

USEPA Method 30B Mercury (Hg)



### The identification of individuals associ ated with the test program is summarized below in Table 2.



## Table 2
Test Personnel

Location Address Contact Test Facility We Energies Valley Power Plant Milwaukee, Wisconsin Ms. Brenda Bergemann (414) 221-2459 (phone) Brenda.bergemann@we-energies.com Testing Company Representative Platt Environmental Services, Inc. 1520 Kensington Road, Suite 204 Oak Brook, Illinois 60523 Mr. Mark E. Peterson Senior Project Manager (630) 521-9400 (phone) mpeterson@plattenv.com



### The test crew consisted of Messrs. J. Howe, J. Zeiss, A. Sczygielski, Rich Sollars, Rod Sollars, D. Quedens, B. H endricks, M. Platt, and M. Peterson of PES. The purpose of the test program was to evaluate the emissions of the constituents listed in Table 1 to satisfy the USEPA information request.ICR Boiler MACT Emissions R eport PES Report No.: M101602 We Energies-Valley Power Plant Boiler 3 Outlet Duct April 20 through 22, 2010



### 2 

# 2.0 Executive Summary

Selected results of the te st program are summariz ed below, in Table 3. A complete summary of emission test result s follows the narrative portion of this report. 

## Table 3
Test Results

Test Location Test Parameter Emission Rate <PM2.5, filterable, lb/mmBtu 0.0010 >PM2.5, filterable, lb/mmBtu 0.0012
PM, condensable 0.0118 <PM2.5, total, lb/mmBtu 0.0129

Total PM, lb/mmBtu 0.0141 Filterable PM (from M29), lb/mmBtu 0.0025 Sb, lb/mmBtu < 6.09 E-07
As, lb/mmBtu <6.11 E-07
Be, lb/mmBtu < 1.53 E-08
Cd, lb/mmBtu < 1.53 E-08
Cr, lb/mmBtu 5.27 E-04
Co, lb/mmBtu 5.18 E-06
Pb, lbs/mmBtu 1.20 E-06
Mn, lbs/mmBtu 6.75 E-05

Ni, lb/mmBtu 3.08 E-04
Se, lb/mmBtu < 3.95 E-06 Boiler 3 Outlet Duct

Hg, lb/mmBtu 2.08 E-08



### A standard F-Factor of 9780 dscf/mmBtu fo r Bituminous Coal was used in the calculation of the emissions on a lb/ mmBtu basis. Compounds expressed above as less than or equal to values had a fr action or fractions that were below detection limits. Detection limits for eac h fraction were used to determine the emission rate for these compounds.ICR Boiler MACT Emissions R eport PES Report No.: M101602 We Energies-Valley Power Plant Boiler 3 Outlet Duct April 20 through 22, 2010



### 3 

# 3.0 Test Methodology

Emissions testing were conducted followi ng the methods specified in 40 CFR, Part 60, Appendix A and 40CFR63, Appendi x A. Schematics of the sampling trains used and copies of field data sheet s for each test run are included in the Appendix.
The following methodologies were used during the test program:



## Method 1 Sample and Velocity Traverse Determination Test measurement points were selected in accordance with Method 1, 40 CFR, Part 60, Appendix A. The characteristics of the measurement location are summarized below, in Table 4.



## Table 4 Sample Point Selection

Test Location Upstream Distance Downstream Distance Test Parameters Number of Sampling Points Filterable Particulate, Condensable Particulate, Total Particulate, Sb, As, Be, Cd, Cr, Co, Pb, Mn, Ni, and Se 24 Boiler 3 Outlet Duct >0.5 >2.0

Hg 3



## Method 2 Volumetric Flow Rate Determination Gas velocity was measured following Meth od 2, 40 CFR, Part 60, Appendix A, for purposes of calculating stack gas volume tric flow rate. An S-type pitot tube, differential pressure gauge, thermocoupl e and temperature readout were used to determine gas velocity at each sample point. All of t he equipment used was calibrated in accordance with the specificat ions of the Method. Calibration data is presented in the Appendix.ICR Boiler MACT Emissions R eport PES Report No.: M101602 We Energies-Valley Power Plant Boiler 3 Outlet Duct April 20 through 22, 2010



### 4 

## Method 3A Oxygen (O2)/Carbon Dioxide (CO2) Determination A Servomex analyzer was used to determine stack gas oxygen (O 2 

### ) and carbon dioxide content and, by difference, ni trogen content in accordance with Method 3A, 40 CFR, Part 60, Appendix A for purpos es of calculating stack gas molecular weight as well as for calculating emissions on a lb/mmBtu basis. The O 2 

### instrument has a nondisper sive infrared-based detecto r and operates in a range of 0-25%, the CO 2 

### instrument also uses a nondi spersive infrared-based detector and operates in the range of 0-20%. All of the equipment used was calibrated in accordance with the specific ations of the Method.



## OTM27 Filterable Particulate Determination Stack gas filterable particulate c oncentrations and emission rates were determined in accordance with Other Te st Method 27 (OTM27) for determination of particulate matter less than 2.5 micr ons. An Environmental Supply Company, Inc. sampling train was used to sample stack gas at a constant rate, as specified in the Method. Filterable particulate ma tter was separated into two fractions; one containing less than PM 2.5, 

### the other greater than PM 2.5


### .



## OTM 028 Condensable Particulate Determination Stack gas condensable particulate concentrations and emission rates were determined in accordance with the dry draft impinger method, in conjunction with Method OTM27 filterable particulate sampling. Condensable particulate matter was collected in the impinger portion of the Method OTM027 sampling train.
The condensable particulate matter (CP M) was collected in impingers after filterable particulate material was co llected utilizing Method OTM27. The organic and aqueous fractions were then taken to dryness and weighed. The total of all fractions represents the CPM. Compared to the December 17, 1991 promulgated Method 202, this Method includes the addition of a condenser, followed by a water dropout impinger immediately afte r the final heated filt er. One modified Greenburg Smith impinger and an ambient temperature f ilter follow the water dropout impinger. A schematic of the sampling train configured with these changes is found in the Appendix.
CPM was collected in the water dropou t, modified Greenburg Smith impinger and ambient filter portion of the sampling tr ain as described in this Method. The impinger contents were purged with nitrogen (N 2 

### ) immediately after sample collection to remove dissolved sulfur dioxide (SO 2 

### ) gases from the impingers. The impinger solution was then extracted with acetone and methylene chloride (MeCl 2 

### ). The organic and aqueous fractions were dried and the residues weighed. The total of the aqueous and or ganic fractions represents the CPM. The samples were analyzed by PES personnel in Des Plaines, Illinois.ICR Boiler MACT Emissions R eport PES Report No.: M101602 We Energies-Valley Power Plant Boiler 3 Outlet Duct April 20 through 22, 2010



### 5 

## Method 29 Trace Metals Determination Stack gas metals concentrations and emission rates were determined in accordance with Method 29. An Environm ental Supply Company, Inc. sampling train was used to sample stack gas, in the manner specifi ed in the Method. Analyses of the samples collected were conducted by Maxxam Analytics, Inc. Samples were analyzed for the following metals, using Inductively Coupled Argon Plasma emission spectroscopy (I CP): Antimony, Arsenic, Beryllium, Cadmium, Chromium, Cobalt, Lead, Manganese, Nickel, and Selenium. All of the equipment used was calibrated in accor dance with the specifications of the Method. Calibration data is presented in the Appendix.



## Mercury Determination by Method 30B (Sorbent Trap Method) Paired trains were utilized using three (3) te st points at the Boiler 3 Outlet Duct.
Per Method 30B sampling, each sample was collected on the paired in-situ sorbent traps. A tube of silic a was used to capture remaining moisture prior to the sample reaching the gas metering system.
The sample train used for this test program was designed by APEX, Inc. and meet all requirements for Method 30B sampling. Samples were analyzed onsite utilizing an Ohio Lumex, Inc. analyze r for total gaseous mercury.ICR Boiler MACT Emissions R eport PES Report No.: M101602 We Energies-Valley Power Plant Boiler 3 Outlet Duct April 20 through 22, 2010



### 6 

# 4.0 Test Results Summaries

Client: Facility: Test Location: Test Method:

Normal Normal Normal 4/20/10 4/21/10 4/22/10

8:00 8:00 8:15 14:03 13:59 14:17 Run 1 Run 2 Run 3 Average

308.4 306.5 306.6 307.2 7.5% 7.8% 7.4% 7.6% 28.32 28.12 28.14 28.19 123.776 134.068 127.101 128.315 43.066 44.802 44.749 44.206 310,944 323,477 323,096 319,172 187,133 193,166 193,818 191,372

12.8 12.5 12.6 12.6 5.9 6.0 5.9 5.9 101.7 107.2 100.5 103.1

0.0004 0.0003 0.0003 0.0003 0.0007 0.0005 0.0005 0.0006 1.080 0.762 0.807 0.883 0.0013 0.0009 0.0009 0.0010

0.0007 0.0003 0.0002 0.0004 0.0012 0.0004 0.0003 0.0006 1.915 0.709 0.536 1.053 0.0023 0.0008 0.0006 0.0012

0.0037 0.0035 0.0037 0.0036 0.0062 0.0058 0.0062 0.0061 9.938 9.566 10.366 9.957 0.0121 0.0113 0.0121 0.0118

0.0041 0.0038 0.0040 0.0040 0.0069 0.0063 0.0067 0.0066 11.0180 10.3280 11.1730 10.840 0.0134 0.0122 0.0130 0.0129

0.0048 0.0041 0.0042 0.0044 0.0081 0.0067 0.0070 0.0073 12.9330 11.0370 11.7090 11.893 0.0157 0.0130 0.0136 0.0141 grains/dscf Stack Conditions End Time

Average %CO 2 by volume, dry basis

Average %O 2 by volume, dry basis

Gas Volumetric Flow Rate, acfm Gas Volumetric Flow Rate, dscfm Average Flue Pressure, in. Hg

Isokinetic Variance

lb/hr lb/mmBtu (Standard Fd Factor) We Energies Valley Power Plant Boiler 3 Outlet Duct

Average Gas Velocity, ft/sec Source Condition Date Start Time

Average Gas Temperature, °F

grains/acf grains/dscf lb/hr lb/mmBtu (Standard Fd Factor) Condensable PM (OTM28) grains/acf grains/dscf lb/hr lb/mmBtu (Standard Fd Factor) lb/mmBtu (Standard Fd Factor)

grains/acf Total PM Filterable >PM2.5 (OTM27) OTM27/OTM28

grains/dscf Filterable <PM2.5 (OTM27)

lb/hr grains/acf Gas Sample Volume, dscf Flue Gas Moisture, percent by volume

Total PM<2.5 grains/acf grains/dscf lb/hr lb/mmBtu (Standard Fd Factor)ICR Boiler MACT Emissions R eport PES Report No.: M101602 We Energies-Valley Power Plant Boiler 3 Outlet Duct April 20 through 22, 2010



### 7 Client: Facility: Test Location: Test Method:

Normal Normal Normal 4/20/10 4/21/10 4/22/10

8:00 8:00 8:16 12:09 12:07 12:26 Run 1 Run 2 Run 3 Average

307.9 306.9 306.2 307.0 8.3% 8.0% 7.8% 8.0% 28.32 28.12 28.14 28.19 122.211 147.658 147.529 139.133 39.864 42.140 41.965 41.323 287,824 304,257 302,995 298,359 171,726 181,078 181,080 177,961

12.8 12.5 12.6 12.6 5.9 6.0 5.9 5.9 92.5 98.5 98.4 96.5

0.0005 0.0009 0.0008 0.0007 0.0009 0.0016 0.0013 0.0013 1.282 2.449 2.094 1.942 0.0017 0.0031 0.0026 0.0025 Method 5 from M29 Train

grains/dscf Filterable PM (Method 29)

lb/hr grains/acf

lb/mmBtu (Standard Fd Factor) We Energies Valley Power Plant Boiler 3 Outlet Duct

Average Gas Velocity, ft/sec Source Condition Date Start Time

Average Gas Temperature, °F

Gas Sample Volume, dscf Flue Gas Moisture, percent by volume Stack Conditions End Time

Average %CO 2 by volume, dry basis

Average %O 2 by volume, dry basis

Gas Volumetric Flow Rate, acfm Gas Volumetric Flow Rate, dscfm Average Flue Pressure, in. Hg

Isokinetic VarianceICR Boiler MACT Emissions R eport PES Report No.: M101602 We Energies-Valley Power Plant Boiler 3 Outlet Duct April 20 through 22, 2010



### 8 Client: Facility: Test Location: Test Method:

Normal Normal Normal 4/20/10 4/21/10 4/22/10

8:00 8:00 8:16 12:09 12:07 12:26 Run 1 Run 2 Run 3 Average

307.9 306.9 306.2 307.0 8.3% 8.0% 7.8% 8.0%
28.32 28.12 28.14 28.19 122.211 147.658 147.529 139.133 39.864 42.140 41.965 41.323 287,824 304,257 302,995 298,359 171,726 181,078 181,080 177,961

12.8 12.5 12.6 12.6 5.9 6.0 5.9 5.9 92.5 98.5 98.4 96.5

< 0.160 < 0.132 < 0.132 < 0.141 < 0.809 < 0.670 < 0.670 < 0.716 < 5.20E-04 < 4.54E-04 < 4.55E-04 < 4.76E-04 < 6.88E-07 < 5.70E-07 < 5.70E-07 < 6.09E-07

< 0.260 < 0.215 < 0.215 < 0.230 < 0.809 < 0.670 < 0.670 < 0.716 < 5.20E-04 < 4.54E-04 < 4.55E-04 < 4.76E-04 < 6.88E-07 < 5.74E-07 < 5.70E-07 < 6.11E-07

< 0.540 < 0.447 < 0.447 < 0.478 < 0.202 < 0.167 < 0.168 < 0.179 < 1.30E-04 < 1.14E-04 < 1.14E-04 < 1.19E-04 < 1.72E-07 < 1.43E-07 < 1.43E-07 < 1.53E-07

< 0.043 < 0.036 < 0.036 < 0.038 < 0.202 < 0.167 < 0.168 < 0.179 < 1.30E-04 < 1.14E-04 < 1.14E-04 < 1.19E-04 < 1.72E-07 < 1.43E-07 < 1.43E-07 < 1.53E-07

164.529 479.974 212.108 285.537 355.900 1038.251 458.818 617.656 2.29E-01 7.04E-01 3.11E-01 4.15E-01 3.03E-04 8.89E-04 3.90E-04 5.27E-04

1.645 4.207 1.565 2.472 4.034 10.315 3.837 6.062 2.59E-03 7.00E-03 2.60E-03 4.06E-03 3.43E-06 8.83E-06 3.26E-06 5.18E-06

0.214 0.107 0.167 0.163 1.841 0.926 1.443 1.403 1.18E-03 6.28E-04 9.79E-04 9.30E-04 1.57E-06 7.93E-07 1.23E-06 1.20E-06

20.002 34.154 49.713 34.623 45.723 78.071 113.638 79.144 2.94E-02 5.30E-02 7.71E-02 5.31E-02 3.89E-05 6.69E-05 9.67E-05 6.75E-05

110.606 251.068 81.443 147.706 270.181 613.292 198.944 360.806 1.74E-01 4.16E-01 1.35E-01 2.42E-01 2.30E-04 5.25E-04 1.69E-04 3.08E-04

2.269 < 1.150 0.809 < 1.409 7.455 < 3.779 2.657 < 4.630 4.80E-03 < 2.56E-03 1.80E-03 < 3.05E-03 6.34E-06 < 3.24E-06 2.26E-06 < 3.95E-06 We Energies Valley Power Plant Boiler 3 Outlet Duct

Source Condition 29

End Time

Average Gas Temperature, °F

Average Flue Pressure, in. Hg Date

ug/dscm Gas Sample Volume, dscf

Average %O 2 by volume, dry basis Start Time

Stack Conditions

Flue Gas Moisture, percent by volume

Antimony (Sb) Emissions Isokinetic Variance Gas Volumetric Flow Rate, dscfm Average %CO 2 by volume, dry basis

Cadmium (Cd) Emissions ppb

lb/hr lb/mmBtu

ug/dscm lb/mmBtu

Beryllium (Be) Emissions

ug/dscm ppb ug/dscm ppb

lb/mmBtu ppm

lb/hr

ppb lb/hr lb/mmBtu

ppb Chromium (Cr) Emissions Average Gas Velocity, ft/sec Gas Volumetric Flow Rate, acfm

ug/dscm Arsenic (As) Emissions lb/hr

ug/dscm Cobalt (Co) Emissions lb/hr

ppb lb/hr lb/mmBtu

ppb ug/dscm Lead (Pb) Emissions lb/mmBtu

ug/dscm Nickel (Ni) Emissions lb/hr

lb/hr lb/mmBtu lb/mmBtu

ppb ug/dscm

Manganese (Mn) Emissions

lb/hr lb/mmBtu

lb/mmBtu Selenium (Se) Emissions ppb ug/dscm lb/hrICR Boiler MACT Emissions R eport PES Report No.: M101602 We Energies-Valley Power Plant Boiler 3 Outlet Duct April 20 through 22, 2010



### 9 Test No. Date Start Time End Time V m (standard L) ng detected ppb ug/dscm ug/wscm lbs/mmBtu (Fd Factor)

1A 4/20/2010 8:05 12:05 542.620 19.00 4.20E-03 0.04 0.03 2.98E-08

1B 4/20/2010 8:05 12:05 531.498 20.00 4.51E-03 0.04 0.03 3.20E-08

19.50 4.35E-03 0.04 0.03 3.09E-08

2A 4/21/2010 8:00 12:00 457.657 10.00 2.62E-03 0.02 0.02 1.87E-08

2B 4/21/2010 8:00 12:00 447.071 10.00 2.68E-03 0.02 0.02 1.92E-08

10.00 2.65E-03 0.02 0.02 1.89E-08
3A 4/22/2010 8:20 12:20 456.941 6.50 1.71E-03 0.01 0.01 1.21E-08

3B 4/22/2010 8:20 12:20 446.902 7.00 1.88E-03 0.02 0.01 1.33E-08

6.75 1.79E-03 0.01 0.01 1.27E-08

12.08 2.93E-03 0.02 0.02 2.08E-08 Method 30B (Sorbent Trap) Mercury Test Results Summary We Energies Valley Power Plant Unit 3 Duct

Overall Average

Run 3 Average Run 1 Average

Run 2 AverageICR Boiler MACT Emissions R eport PES Report No.: M101602 We Energies-Valley Power Plant Boiler 3 Outlet Duct April 20 through 22, 2010



### 10 

# 5.0 Conclusion and Certification

PLATT ENVIRONMENTAL SERVICES is pl eased to have been of service to We Energies. If you have any questions regarding this test report, please do not hesitate to contac t us at 630-521-9400.


## CERTIFICATION

As project manager, I hereby certify that this test report represents a true and accurate summary of emi ssions test results and the methodologies employed to obtain those results, and the test program was perfo rmed in accordance with the methods specified in this test report.

PLATT ENVIRONMENTAL SERVICES

________________________ __________ Program Manager Mark E. Peterson

________________________ __________ Quality Assurance Jeffrey M. Crivlare

# APPENDIX