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# OAR Box 1105 Prepped byCandice Davis



### Document

Number: 

# 106)l-A- 3 Docket Number: 

# A-80-2 6

Printed 4/14/2008 3:11:59 PM

Sheet 106 of 131P. 2



### INSPECTIONMANUAL FOR TH E ENFORCEMENT O F NE W SOURC E PERFORMANC E STANDARDS : COAL PREPARATIONPLANT S

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# '\-.'/ Y Contrac t No . 68-01-315 0 EPAProjec t Officer : Mar k Antel l

Prepare d for : U.S . ENVIRONMENTAL PROTECTIONAGENC Y Divisio n o f StationarySourc e Enforcemen t

Washington , D.C . Augus t 197 7P. 3



### Thi s repor t wa s furnishe d t o the U.S . Environmenta l Protec tio n Agenc yb

yPEDC o Environmental , Inc. , Cincinnati , Ohio , i n fulfillmen t o f Contrac t No % 

### 68-01-3150 . Th e content s o f thi s repor t ar e reproduce d herei n a s receive d fromth e contractor . Th e opinions , finding s an d conclusion s expresse d ar e thos e o f th e author s an d no t necessaril ythos e o f th e U.S . Environmenta l Protectio n Agency .

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### ACKNOWLEDGMENT Thi s repor t wa s prepare d fo r the U.S . Environmenta l Protectio n Agenc yb yPEDC o Environmental , Inc. , Cincinnati , Ohio . Th e Projec t Directo r wa s Mr . Timoth yW . Devitt ; the Projec t Manager , Mr . Yatendr a M . Shah . Principa l author s wer e Messrs . Jame s R . Burke , Norma n J . Kulujian , an d Yatendr a M . Shah . Mr . Mar k Antel l wa s Projec t Office r fo r the U.S . Environmenta l Protectio n Agency . Th e author s appreciat e the contribution s mad e t o thi s stud yb yMr . Antel l an

d othe r member s o f the U.S . Environmenta l Protectio n Agency .

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TABL E O F CONTENT S
1. 0 INTRODUCTIO N 2. 0 SUMMAR Y O F NSP S REGULATION S 2. 1 Applicabilit yan d Designatio n o f Affecte d Facilit y 2. 2 Definition s 2. 3 Emissio n Standard s fo r Particulat e Matte r 2. 4 Monitorin g o f Operation s 2. 5 Tes t Method s an d Procedure s 3. 0 COA L PREPARATIO NINDUSTR Y 3. 1 Coa l Market s 3. 2 Purpos e o f Coa l Preparatio n 3. 3 Developmen t o f Minin g Method s an d Changin g Preparatio n Standard s 3. 4 Locatio n o f Coa l Preparatio n Plant s 3. 5 Economic s o f Coa l Preparatio n 4. 0 PROCES S DESCRIPTIO N 4. 1 Capabilitie s o f Coa l Preparatio n 4. 2 Applicatio n o f Cleanin g Processe s t o Siz e Increment s 4. 3 Coa l Sizin g 4. 4 Pneumati c Cleanin g Pag e 1- 1 2- 1 2- 1 2- 1 2- 2 2- 2 2- 3 3- 1 3- 2 3- 2 3- 3 3- 5 3- 9 4- 1 4- 2 4- 4 4- 5 4- 9

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### TABL E O F CONTENT S (continued ) Pag e 4. 5 Jig-Tabl e Washin g 4-1 2 4. 6 Heavy-Medi a Washin g Plan t 4-1 5 4. 7 Wate r Clarificatio n Plan t 4-1 9 4. 8 Therma l Drying 4-2 2 4. 9 Emissio n Source s an d Contro l Device s 4-2 6 4.1 0 Contro l Devices , Thei r Capabilitie s an d 4-2 7 Efficiencie s 5. 0 INSTRUMENTATIONAND RECORD S 5- 1 5. 1 Proces s Instrumentatio n 5- 2 5. 2 Record s 5- 5 6. 0 START-UP , SHUTDOWN , AND MALFUNCTION S 6- 1 6. 1 Start-u

p an d Shutdow

n 6- 1 6. 2 Change s i n Coa l Fee d 6- 3 6. 3 Malfunctio n o f Suppor t Equipmen t 6- 4 6. 4 Malfunctio n i n Source s o f Fugitiv e Dus t 6- 5 6. 5 Malfunctio n o f Contro l Device s 6-1 3 7. 0 EMISSIONPERFORMANC E TEST S 7- 1 7. 1 Pretes t Procedure s 7- 1 7. 2 Tes t Monitorin g 7- 5 8. 0 PERIODI C COMPLIANC E INSPECTION S 8- 1 8. 1 Performing th e Periodi c Inspectio n 8- 1 8. 2 Determinin g Complianc e Statu s 8-1 3 REFERENCE S 8-1 5

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### TABL E O F CONTENT S (continued ) Pag e APPENDI X ANE W SOURC E PERFORMANC E STANDARD S A- 1

COAL PREPARATIONPLANT S APPENDI X B STANDARD TES T METHOD S B- 1

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### LIS T O F FIGURE S No . Pag e 3- 1 Trend s i n Coa l Productio n an d Coa l Cleanin g 3- 6 3- 2 Illustrativ e Cleanin g Circui t 3-1 0 4- 1 Coa l Sizing Circui t 4- 6 4- 2 Hammermil l 4- 7 4- 3 RotaryBreake r 4- 7 4- 4 Pneumati c Cleaning Circui t 4-1 0 4- 5 Ai r Tabl e 4-1 1 4- 6 Ji g Tabl e Cleanin g Circui t 4-1 3 4- 7 Air-Pulsate d Ji g 4-1 4 4- 8 Deiste r Tabl e 4-1 4 4- 9 Heavy-Medi a Cleanin g Circui t 4-1 6 4-1 0 Heavy-Medi a Cyclon e 4-1 7 4-1 1 Wate r Clarificatio n Circui t 4-2 0 4-1 2 Frot hFlotatio n Uni t 4-2 1 4-1 3 Fluid-Be d Drye r 4-2 3 4-1 4 Multilouve r Drye r 4-2 4 4-1 5 Cascad e Drye r 4-2 4 4-1 6 Flas hDrye r 4-2 5

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# I LIS T O F TABLE S

No . Pag e 2- 1 Compariso n o f NSP S an d Stat e Emissio n 2- 5 Regulation s 3- 1 Locatio n o f Coa l Washin g Capacit yan d 3- 8 Bituminous/Lignit e Coa l Productio n 3- 2 Cos t Analysis , Ra wan d Washe d Coal s 3-1 3 3- 3 Illustrativ e Preparatio n Costs , Easter n 3-1 5 Kentuck yCoal s 3- 4 Illustrativ e Preparatio n Costs , Wes t 3-1 7 Virgini a Coal s 4- 1 Coa l Siz e Range s fo r Cleanin g Equipmen t 4- 4 4- 2 Cyclon g Variable s 4-2 8 4- 3 Scrubbe r Variable s 4-2 9 4- 4 Orific e Flo wRate s 4-3 0 4- 5 Operatin g Temperature s 4-3 1 7- 1 Emissio n Performanc e Tes t Responsibilitie s 7- 6 7- 2 Checklis t fo r Performanc e Tes t 7- 7 8- 1 Checklis t fo r Periodi c Inspectio n 8- 2

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# I X 

### 1. 0 INTRODUCTIO N O n Octobe r 24 , 1974 , unde r Sectio n 11 1 o f the Clea n Ai r Act , a s amended , th e Environmenta l Protectio n Agenc ypro pose d standard s o f performanc e fo r ne wan d modifie d coa l preparatio n plants . Th e propose d standard s wer e modifie d o n the basi s o f comment s receive d fro mvariou s intereste d parties . Th e Federa l Registe r o f January15 , 1976 , present s : | th e standard s o f performanc e fo r ne wan d modifie d coa l I preparatio n plants . k Thi s repor t present s procedure s fo r inspectio n o f coa l 

# I | preparatio n facilitie s toward determinatio n o f thei r com r t

### plianc e wit hNe wSourc e Performanc e Standard s (NSPS ) . I t ] als o provide s background informatio n tha t wil l ai d th e 

# i inspecto r i n understanding th e coa l preparatio n proces s an d the effect s o f operating parameter s o n proces s emissions . Sectio n 2. 0 deal s wit hth e emissio n regulation s fo r th e coa l preparatio n industry , presenting a brie f historyo f NSPS , a discussio n o f th e nee d fo r modification s o f th e propose d standards , an d a summaryo f emissio n regulations , including monitorin g an d recordkeeping requirements . Regulation s o f individua l state s pertaining t o coa l prepara tio n plant s ar e compare d wit hth e NSPS . &



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### Background informatio n o n the coa l preparatio n industry i s presente d i n Sectio n 3.0 , whic hdescribe s th e purpos e o f coa l preparation , marke t requirements , marke t trends , geo graphi c locatio n o f plants , an d th e economic s o f coa l preparation . i Sectio n 4. 0 describe s th e coa l preparatio n proces s an d th e majo r proces s variations , outlining th e functio n o f proces s equipment , th e potentia l emissio n points , an d th e emissio n contro l technique s currentl yi n us e i n the coa l preparatio n industry . Instrumentatio n an

d record-keepin g practice s o f the newe r plant s ar e discusse d i n Sectio n 5.0 . Sectio n 6. 0 deal s wit hemission s tha t occu r durin g start-up , shutdown , an d malfunction , wit hoperationa l procedure s fo r maintainin g suc hemission s a t o r belo wth e require d levels . Sectio n 7. 0 present s i n detai l th e inspectio n procedur e an d chec k point s fo r observatio n durin g performanc e tests . Tes t duration , operating conditions , an d interpretatio n o f instrumen t indication s ar e discussed . Sectio n 8. 0 outline s periodi c inspectio n procedure s an d th e relationshi p o f periodi c inspectio n dat a t o thos e ob
taine d i n th e initia l performanc e test .

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### Th e NSP S a s presente d i n th e Federa l Registe r ar e reproduce d i n Appendi x A . Appendi x B present s standar d tes t procedures .

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$'• 

# f 2. 0 SUMMAR Y O F NSP S REGULATION S Th e following summar yo f Ne wSourc e Performanc e Stan dard s fo r coa l preparatio n plant s i s give n i n a forma t corresponding t o tha t use d i n th e Federa l Register , a s reproduce d i n Appendi x A . Regulation s propose d b yindi
vidua l state s ar e discusse d briefly . 2. 1 APPLICABILIT Y AND DESIGNATIONO F AFFECTE D FACILIT Y Coa l preparatio n plant s processing les s than 20 0 ton s pe r da yo f coa l ar e exempte d b ythe NSPS . Th e affecte d facilitie s i n the coa l preparatio n plant s processin g mor e than 20 0 ton s pe r dayar e therma l dryers , pneumati c coa l cleaning equipmen t (ai r tables) , coa l processing an d con veying equipmen t (includin g breaker s an

d crushers) , coa l storag e systems , an d coa l transfe r an

d loading facilities . 2. 2 DEFINITION S Underground minin g operation s ar e no t considere d par t o f the coa l preparatio n process . Coa l storag e an d transfe r source s ar e governe d b yNSP S onl yi f theyfor ma par t o f th e coa l preparatio n facility ; isolate d coa l storag e an d transfe r station s ar e excluded . Ope n coa l storag e pile s ar e exclude d fro mth e definitio n o f coa l storag e systems .

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### 2. 3 EMISSIONSTANDARD S FOR PARTICULAT E MATTE R Regulation s fo r emission s o f particulat e matte r fro m coa l processing facilitie s ar e a s follows : 2.3. 1 Therma l Drye r Exhaus t gase s discharge d int o atmospher e shal l no t contai n particulat e matte r i n exces s o f 0.07 0 gram/dry standar d cubi c mete r (g/dscm ) o r 0.03 1 grain/drystandar d cubi c foo t (gr/dscf ) an d shal l no t exhibi t 2 0 percen t o r greate r opacity . 2.3. 2 Pneumati c Coa l Cleaning Equipmen t (Ai r Table ) Th e gase s discharge d int o atmospher e froman ai r tabl e shal l no t contai n particulat e matte r i n exces s o f 0.04 0 g/dscm(0.01 8 gr/dscf ) an d shal l no t exhibi t 1 0 percen t o r greate r opacity . 2.3. 3 Othe r Facilitie s Th e gase s discharge d int o atmospher e fro mothe r coa l conveying , processing , an d storag e an

d transfe r facilitie s shal l no t exhibi t 2 0 percen t o r greate r opacity . 2. 4 MONITORIN

G O F OPERATION S Th e NSP S regulation s requir e continuou s monitorin g o f exi t ga s temperatur e o n th e therma l dryer . I f a ventur i scrubbe r i s use d t o contro l emission s fro mthe therma l dryer , continuou s monitorin g o f wate r suppl ypressur e an d o f pressur e los s throughth e ventur i constrictio n ar e required . 

### i

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### 2. 5 TES T METHOD S AND PROCEDURE S Th e regulation s prescrib e standar d tes t method s an d procedure s fo r particulat e emissio n measurements . Metho d 5 i s t o b e use d fo r th e concentratio n o f particulat e matte r an d associate d moistur e content , metho d 1 fo r sampl e an d velocit ytraverse , metho d 2 fo r velocit yan d volumetri c flow rate , an

d metho d 3 fo r ga s analysis . Th e sampling time fo r metho d 5 i s a t leas t 6 0 minutes , an d the minimu

msampl e volume i s 30. 0 dscf . Sampling i s no t t o b e starte d unti l 3 0 minute s afte r start-u p an d i s t o b e terminate d befor e shut
dow n procedure s commence . Standar d tes t method s ar e give n i n Appendi x B . Mos t o f the state s hav e n o separat e emissio n regula
tion s fo r coa l preparatio n plants , whic husuall yar e encom passe d unde r proces s emissio n regulations . Thre e easter n coal-producing state s - Pennsylvania , Virginia , an d Wes t Virgini a - an

d the Stat e o f Ne wMexic o hav e formulate d regu lation s fo r coa l preparatio n plants . Th e Pennsylvani a regulation s stat e a singl e allowabl e emissio n rat e o f 0.0 2 gr/dsc f fo r therma l dryer s an d ai r tables . Th e concentratio n fo r therma l dryer s i s mor e stringen t tha n the NSP S allowabl e concentratio n o f 0.03 1 gr/dscf ; th e NSP S allowabl e emissio n rat e fo r ai r table s i s 0.01 8 gr/dscf . Th e Virgini a regulation s allo w10 5 pound s

2- 3._EJfi_ ,



### pe r hou r o f particulat e emission s fro mtherma l dryer s pro cessing 20 0 ton s pe r hou r o r mor e coal . Allowabl e emission s fromth e ai r tabl e ar e 0.0 5 gr/dscf . Th e Wes t Virgini a regulation s fo r therma l dryer s installe d afte r Marc h1 , 1970 , rang e from0.0 7 t o 0.1 0 gr/dscf . Allowabl e emission s fro man ai r tabl e ar e 0.0 5 gr/dscf . Ne wMexic o Stat e regu lation s requir e goo d contro l o f coa l processin g an d con veying operations ; n o quantitativ e limit s ar e specified . A compariso n o f NSP S regulation s an d thes e Stat e regulation s i s presente d i n Tabl e 2.1 .

2- 4Tabl e 2-1 . NSP S AN D STAT E EMISSIO NREGULATION S

I Coa l processin g

facilit y Therma l drye r

Ai r tabl e
Processin g and conveyin g NSPS
0.03 1 gr/dsc f Opacity : les s than 2 0 percen t 0.01 8 gr/dsc f Opacity : les s tha n 1 0 percen t Opacity : les s tha n 2 0 percen t Particulat e Pennsylvani a
0.02 0 gr/dsc f

0.02 0 gr/dsc f

N o regulatio n matte r emissio nregulatio n Virgini a 10 5 lb/h r

0.0 5 gr/dsc f

N o regulatio n Wes t Virgini a

Ga s flow , scf m 75,00 0 o r les s 111,00 0 o r les s 163,00 0 o r les s 240,00 0 o r abov e gr/dsc f 0.1 0 0.0 9 0.0 8 0.0 7 0.0 5 gr/dsc f
Fugitiv e dus t contro l syste m require d Ne w Mexic o
N o regulatio n

N o regulatio n Fugitiv e dus t contro l system require dP.1 8



## b 3. 0 COAL PREPARATIONINDUSTR Y I n th e earl ypar t o f thi s centuryeffort s t o prepar e coa l wer e directe d t o sizing th e coa l t o suppl ylum p coa l fo r domesti c us e an d intermediat e size s fo r industria l o r bunke r use ; th e fine s wer e usuall yrejecte d a s unfi t fo r sale . Developmen t o f sizing facilitie s t o mee t th e demand s o f the midcenturycoa l consume r resulte d i n highl ysophis
ticate d handling an d screening facilities . Today' s marke t require s les s sizing than eve r before , th e primarylimita
tio n being maximu

msiz e fo r shipment . Sinc e th e veryearl yday s o f mining , attempt s hav e bee n mad e t o improv e the qualit yo f coa l b yremoving slate . Thes e effort s wer e mad e i n th e underground mine s unti l th e adven t o f mechanica l mining , supporte d b yhan d picking i n the "tipple " outsid e the mine . Th e firs t washin g wa s don e i n Bau man d Norto n jig s importe d fro mEurope , followe d b yth e introductio n o f the "Chance " washe r i n 1918 . Th e latte r wa s an excellen t washe r utilizing san d an d wate r a s a medium , whic hha s sinc e bee n displace d b ythe "heav

ymedia " proces s using magnetite . Throughth e years , man yothe r type s o f washer s hav e bee n introduce d an d hav e bee n abandoned .

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I



### Jh = Th e mean s o f dryin g hav e bee n improved , althoug hth e

origina l screenin g equipmen t ha s bee n supplemente d onl yb y centrifuges . Th e adoptio n o f Dieste r table s nea r th e middl e o f th e centur yt o was hfin e coa l require d supplementar yequipmen t includin g centrifuges , frot hflotatio n devices , dis c filters , thickeners , cyclones , an d therma l dryers . 3. 1 COA L MARKET S Unti l th e middl e o f th e dentur yth e primar ycoa l market s wer e domestic , transportatio n (rai l an d ship) , metallurgical , an d industrial . A t presen t th e primar ycoa l market s ar e fo r utilit yan d metallurgica l us e an d fo r export . Th e utilit ymarke t use s low-qualit ycoals . Th e metallurgica l marke t require s th e ver ybes t coals , com pletel yprepared . Th e expor t marke t utilize s a qualit y somewha t lowe r tha n tha t o f th e metallurgica l coals . 3. 2 PURPOS E O F COA L PREPARATIO N Coa l preparatio n serve s severa l purposes . On e importan t purpos e i s t o increas e th e heatin g valu e o f th e coa l by mechanica l remova l o f impurities . Thi s i s ofte n require d i n orde r t o find a marke t fo r th e product . Run-of-min e coa l fro m a moder n min e ma yincorporat e a s muc ha s 6 0 percen t rejec t materials .

3- 2

### Ai r pollutio n contro l ofte n require s partia l remova l o f

pyrite s wit hth e as ht o reduc e th e sulfur conten t o f th e coal . As hconten t ofte n mus t b e controlle d t o conformt o a prescribe d qualit ystipulate d i n contractua l agreements . Becaus e o f firing characteristics , i t i s ofte n a s importan t t o retai n th e as hconten t a t a give n leve l a s i t i s t o reduc e it . Freigh t saving s ar e substantia l whe n impuritie s ar e remove d prio r t o loading . Finally , th e rejecte d impuritie s i 

### iar e mor e easil ydispose d o f a t th e min e sit e remot e fro m 

# I | citie s than a t th e burning site , whic hi s usuall yi n a %populate d area .

! i l i % 

### I i i 

### 3. 3 DEVELOPMENT OF MININ G METHOD S AND CHANGIN G PREPARATION STANDARD S Th e earlies t mining systemuse d i n England , fro mwhic h U.S . practice s evolved , wa s th e longwal l method . Mining coul d procee d fro

m th e shaf t onl ya shor t distanc e becaus e no force d ventilatio n wa s available . Al l the coa l withi n thi s perimete r wa s remove d prio r t o extending th e shaf t deepe r o r sinking a ne wone . No coa l preparatio n o f con sequenc e wa s performe d a t thi s time . Th e room

an d pilla r metho d wa s use d i n underground mine s i n thi s countrybecaus e o f th e natur e o f an d eas y accessibilit yo f th e coa l beds . Stri p minin g wa s introduce d during th e secon

d decad e o f thi s century , afte r th e develop
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I I 

### men t o f th e stea mshove l fo r th e Panama Canal , an d th e longwal l systemwa s reintroduce d o n an experimenta l basi s during the las t 2 0 years . Auge r minin g wa s introduce d wit h th e spread o f coa l stripping , a s a supporting metho d o f recoving coal s fromunderneat ha highwall . Coa l i s produce d currentl yb yth e following methods : Underground minin g 4 5 percen t Mine d b yhand 0. 7 Conventiona l minin g 15. 0 Continuou s minin g 27. 7 Longwal l minin g 1. 6 Stri p minin g 5 5 percen t Unti l Worl d Wa r I I mos t coa l wa s loade d b yhan d an d wa s obtaine d fro

mth e bette r seam s o f coal . Eac hworke r wa s responsibl e fo r rejecting impuritie s an d (sometimes ) fine s i n the mine . Outsid e preparatio n equipmen t consiste d o f screens , crushers , an d picking tables . Washerie s wer e no t common . Exhaustio n o f th e bes t coal s an d adoptio n o f mechanica l mining , whic heliminate d th e remova l o f impuritie s i n the mine , require d th e wide r us e o f cleanin g plant s incorpora
ting screens , crushers , picking tables , an d washers . Thes e plant s normall ypractice d han d picking fo r the lum p an d eg g size s (mor e than 3 inches ) an d washe d the coarse r coa l ( 3 in . x 1/ 4 in.) . Th e fin e coa l (1/ 4 x 0 ) wa s usuall yshippe d raw . Th e rejec t fro msuc ha plan t wa s unlikel yt o excee d 1 0 percen t o f th e run-of-min e (ROM ) coal .
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## f i Introductio n o f th e continuou s mine r requiring "ful l

seam " mining , eliminatio n o f a larg e portio n o f the domesti c market , an

d furthe r exhaustio n o f the bes t coal s impose d furthe r requirement s o n the coa l preparatio n plants . The y \l wer e require d t o clea n an d dryth e 1/ 4 x 0 coa l fraction , th e 

# If stat e o f developmen t tha t i s curren t today . Picking table s

hav e bee n eliminated , a fine-coa l circui t ha s bee n added , an d rejectio n o f 5 0 percen t o f the ROM coa l i s no t uncommon . Fluctuation s i n coa l demand resulte d i n the dismantlin g o f plants , some o f whic hwer e incorporate d int o othe r o r ne w plants , alway s o f large r capacities . Th e tren d ha s bee n t o utiliz e on e larg e plan t t o proces s coa l fromsevera l mines , eve n fro

m differen t seams , a t th e expens e o f additiona l freigh t charge s an

d intensifie d refus e disposa l require
ments . Figur e 3- 1 indicate s the trend s i n th e coa l prepara tio n industry . Some plants , modifie d an d expande d severa l times , ar e I 1|

- stil l operating a t th e origina l sit e afte r 5 0 years , long

afte r the origina l min e ha s bee n abandoned . 3. 4 LOCATIONO F COAL PREPARATIONPLANT S Genera l Consideration s Larg e coa l washin g plant s ar e normall ylocate d i n th e mining area s t o accommodat e on e o r mor e mines . Theyar e concentrate d nea r th e highest-qualit ycoal s becaus e o f proces s economic s an d marke t factors .

3- 5I l\J\J

600

50 0

tn 40 0 z . o (tD O „ « 30 0 z f = 3COAL 20 0

100 ^~^\

-

>

v

- ANNUAL COAL PRODUCTION ^

• COA L MECHANICALL YCLEANE D -

-

-

-

194 7 6 2 6 3 6 4 6 5 6 6 6 7 6 « 6 9 7 0 71 7 2 7 3 7 4 7 5 YEA RO F PRODUCTIO

N 

### Figur e 3-1 . Trend s i n coa l productio n an d coa l cleaning ,P.2 4



### ? 3 Afe wwashin g plant s locate d a t rive r loadin g site s ar e

serve d byrailroad s wit hra wcoa l fro mth e mine s an d dispos e o f th e refus e nea r th e plant . Coa l screenin g an d crushin g plant s ar e site d a t widel y scattere d location s whereve r coa l ma yb e used , particularl y a t cok e plants , coa l yards , powe r plants , an d industria l plants . The yar e als o foun d a t al l min e loadin g sites . Tabl e 3- 1 give s location s o f majo r plants . Sitin g Consideration s Sitin g o f coa l preparatio n plant s i s base d o n th e followin g considerations : a . Lengt ho f haul . Optimu mlocatio n i s a t shortes t possibl e distanc e fro mth e mine . b . Acces s t o transportatio n b yrailwa yo r barge . c . Wate r supply . Th e plan t mus t b e provide d wit h substantia l amount s o f wate r fro mwells , streams , o r impoundments . d . Suitabl e terrain . Leve l area s ar e require d fo r thickener s an d slurr yponds ; larg e area s mus t b e suitabl e fo r refus e disposal . Transportatio n o f Ra wMateria l Ashaf t min e discharge s coa l directl yint o th e plan t withou t intermediat e transportation . Coa l i s als o delivere d directl yfro mth e min e bybel t conveyo r o r min e car s whe n th e plan t i s adjacen t t o th e min e mouth .

3- 7

### Tabl e 3-1 . LOCATIONO F COAL WASHIN G CAPACITY Ai . BITUMINOUS/LIGNIT E COAL PRODUCTIO N

Stat e Alabam a Alask a Arizon a Arkansa s Colorad o Illinoi s Indian a Iow a Kansa s Kentuck y Marylan d Missour i Montan a Ne wMexic o Nort hDakot a Ohi o Oklahom a Pennsylvani a Tennesse e Texa s Uta h Virgini a Washingto n Wes t Virgini a Wyomin g Tota l Productio n capacit y 1974 , thousan d ton s 19,74 5 71 6 6,43 2 44 5 6,96 0 58,08 0 25,26 7 68 0 67 9 133,00 0 2,17 0 4,62 5 14,08 9 9,66 9 7,40 0 44,56 6 2,37 5 78,87 9 7,68 1 7,68 4 6,04 7 33,24 9 3,91 5 105,99 7 20,65 0 601,00 0 No .

operatin g companie s 3 6 1 1 4 1 1
• 1 4 1 2 7 2 33 8 1 2 3 5 3 5 7 3 7 22 0 4 6 2 1 0 6 9 3 22 2 1 4 •1,12 0 No .

washin g plant s 2 1

3 3 6 9 2 6 9 1 2 1 2 0 6 4 5 5 4 3 1 10 6 1 38 9



### 3- 8P.2 6 (

\


# • f Centra l cleaning plant s ar e serve d b ytrucks , whic hmay hau l coa l 2 0 mile s fromthe mine , an d b yrailcars , whic h hau l rawcoa l t o the plan t an d the n reload wit hclea n coal . "Overland " conveyor s hau l coa l fro mth e min e t o th e plan t ove r distance s u p t o 1 0 miles . On e installatio n move s coa l fro

mmin e t o plan t b

ypipelin e i n a wate r medium . Transportatio n o f Plan t Product s Refus e fro

mcoa l preparatio n usuall yi s haule d t o disposa l area s b

ytrucks . I t i s sometime s move d t o adjacen t valley s b

ybel t conveyor s an d aeria l tramways . Prepare d coa l i s remove d fromthe plan t b yrailway , barge , an

d truck . Asmal l par t i s transporte d b yconveyor s t o powe r plan t stockpile s o r t o loading terminal s fo r long
distanc e shipment . 3. 5 ECONOMIC S O F COAL PREPARATION Th e advantage s o f preparing coa l varywit hthe sea m being mined , the typ e o f mining , an d potentia l markets . Figur e 3- 2 demonstrate s the improvement s mad e i n the coa l tha t coul d b e mine d froma coa l sea mb ycontinuou s miner s i n Indiana , Pennsylvania . Thi s illustratio n represent s a n extreme cas e i n coa l minin g an d preparation . Larg e amount s o f slat e in the ROM materia l resul t i n a heating valu e (HV ) o f 758 0 Btu , whic hi s to o lo wfo r commercia l sale . Rejectio n o f impuritie s produce s a produc t containing 6. 6 percen t as h

3
-RA WCOAL IOO * » - i

CLEA N COAL 54.5 %

RA WCOAL CLEA N COAL REFUS E Figur e 3-2 . 100. 0 54. 5 45. 5 HH

V BTU/L B 756 0 1330 8 675 Illustrativ e cl e * AS H 48. 4 6. 6 98. 5 anin g TOTA L

HEA T CONTEN T 756 0 725 3 30 7 circui t REFUS E 45. S %

% S 5. 0 2. 2 8.3 6



### 3-1 0

### wit ha heating valu e o f 13,30 0 Btu ; suc ha coa l i s readil y

marketable . Th e capacit yo f a boile r i s upgrade d b yus e o f high
heat-conten t coal , offerin g indirec t saving s i n capita l investment , operation , an d maintenance . Th e size s o f stockpile s a t larg e point s o f consumptio n ar e base d o n a require d perio d o f operatio n withou t replen
ishment . Thi s requiremen t ca n b e eas*il ytranslate d int o a give n amoun t o f store d energ y(Btu) . Becaus e a stockpil e containing high-Bt u coa l ca n b e smalle r than on e containin g low-Bt u coal , th e cost s o f material s handling ar e lower . I n th e cas e depicte d i n Figur e 3-2 , a give n stockpil e o f ROM coa l woul d b e 1.7 6 time s large r than a pil e o f prepare d coa l having th e same tota l heating value . Reject s from a cleaning plan t ar e directl ycorrelate d t o the as hproduce d i n a powe r plant . Th e reject s fro ma cleaning plan t ar e muc heasie r t o dispos e o f tha n i s th e as hfroma powe r plant , an d a sub
stantia l saving s ca n b e realize d wher e disposa l i s don e a t the cleaning plant . Apowe r plan t using th e coa l evaluate d i n Fiqur e 3- 2 (45. 5 percen t reject ) woul d b e require d t o handl e 7.2 4 time s a s muc has hi f th e coa l wer e burne d raw rathe r than washed . Rejecting impuritie s a t the min e result s i n a direc t freigh t savings .

3-1 1P.2 9



### I i Tw o cases , illustrating us e o f rawan d washe d coa l fro

m the same mine , ar e analyze d i n Tabl e 3-2 . Cas e 1 assese s th e valu e o f ROM coa l tha t i s shippe d 20 0 mile s t o a powe r plan t an

d sol d fo r $0.70/1 0 Btu . Cas e I I assesse s th e valu e o f th e ROM coa l tha t i s washe d an d shippe d t o th e same plan t fo r th e same price . Coa l preparatio n involve s fiv e differen t steps , com bination s o f whic hconstitut e th e plan t fo r a give n mine . i Ste p 1 - Crushing/screening . Thi s step involve s n o 1 ! 

### > qualit yimprovement , merel ysizing fo r rawshipment . Mos t t ' j 

### j utilit ycoa l i s prepare d thi s way . I f furthe r preparatio n 

# I Ui s involved , a separatio n i s mad e a t 1/4-3/ 8 inch . Thi s step include s al l coa l shipped . Cost s ar e les s than thos e o f othe r steps , ranging fro m$0.1 5 t o $0.3 0 pe r ton . Ste p 2 - We t washin g th e +l/4-inc hsizes . Approxi
matel y7 8 percen t o f al l cleane d coa l i s washe d b ythi s means . Man

yplant s us e onl ythi s step , shipping the 1/ 4 x 0 siz e raw . Cos t o f we t washin g th e +l/4-inc hcoa l range s from $0.2 5 t o $0.5 0 pe r to n o f feed . Ste p 3 - We t washing 1/4-inchx 28 M (2 8 Mesh) . Although no t usuall ypractice d elsewhere , thi s step i s nearl yalway s use d a t larg e underground mines . Approximatel y1 4 percen t o f the cleane d coa l i s washe d b ythi s means . 3-1 2P.3 0



### Tabl e 3-2 . COS T ANALYSIS , RA W AN D WASHE D COAL S

" . , . 72000x758 0 Bt u x $0.7 0 , . i n

### , , Purchas e cos t 1 ton ( 7 ) = $10.6 1 10 ° Bt u Freigh t 20 0 mile s ( 1 to n x 20 0 Mi . x $0,00 9 ) = 1.8 0 Stockpil e cos t = 1.2 0 As hdisposa l (45.5 % x $3.80° ) = 1.7 3 $15.3 4 Actua l cos t o f energ ya t bunke r 200 0 750 0 = $1.01/1 0 Bt u Cas e I I - Washe d coa l t o powe r plant . 

### T . , . „_. . ,200 0 x 1331 0 x 0.54 5 x 0.70 , TTTT7 " Purchas e cos t 1 ton RO M ( 7

) = $10.1 5 

# I 1 0 Freigh t 20 0 mile s (0.54 5 x 20 0 x 0.009 ) = 0.9 8 c Washing cos t = 1.6 0 Refus e disposa l (0.45 5 x $1.20° ) = 0.5 4 Stockpil e cos t (1.2 0 x 0.545 ) = 0.6 5 As hdisposa l (3.8 0 x 0.54 5 x 6.6% ) = 0.1 3 $14.0 5 Actua l cos t o f energ ya t bunke r ( 2 

### QOO—^72~53 ^ = 

### $0.97/1 0 Bt u Fo r thi s analysi s the H V i s belo wacceptabl e values . Th e pric e i s belo wmining cost . Typica l Midwes t uni t trai n rate , 20 0 M M to n mi/yr . c Typica l averag e cost .

3-1 3P.3 1

Cos t o f thi s proces s range s fro m$0. 4 0 t o $0.7 0 pe r to n o f feed . Dr ycleanin g o f th e 1/ 4 x 0 coa l wit hai r table s account s fo r onl y5 percen t o f al l coa l cleaned . I t i s sometime s accompanie d bypretherma l drying . Cos t o f dr ycleanin g i s betwee n $0.2 0 an d $0. 4 0 pe r to n o f feed . Therma l dryin g involve s a n additiona l cost . Ste p 4 - We t washin g the. 2 8 M x 0 , th e leas t commo n method , i s use d wit honl y3 percen t o f th e coa l an d i s usuall yrestricte d t o larg e dee p mine s equippe d wit hcon tinuou s miners . Cost s rang e fro m$0.4 0 t o $0.8 0 pe r to n o f feed . Ste p 5 - Therma l dryin g i s nearl yalway s restricte d t o 1/ 4 x 0 siz e coal , th e exception s bein g application s t o predr ycoa l fo r screenin g prio r t o cleanin g o n ai r tables . Cos t o f dryin g range s fro m$0.6 0 t o $1.2 0 pe r to n o f feed . Cost s fo r eac hste p appl yonl yt o tha t portio n o f th e fee d tha t i s affected , a s indicate d i n Table s 3- 3 an d J-4 . Cost s o f coa l preparatio n ar e dependen t o n scree n analysi s an d amoun t o f reject s a s wel l a s efficienc yo f operatio n an d design/conditio n o f plant . Th e cos t o f processin g i n eac hste p show n i n th e table s i s th e averag e o f th e cos t range s liste d above . Tabl e 3- 3

3-1 4Tabl e 3-3 . ILLUSTRATIV E PREPARATIO NCOSTS , EASTER NKENTUCK Y COAL S

O J I ts. Siz e Ra wcoa l + 1/ 4 in . 1/ 4 x 28 M 28 M x 0 Percen t o f

tota l coa l 100. 0 51. 1 36. 2 12. 7 100. 0 Cost , $/to n

screenin g 0.22 5 washin g

0.37 5 0.5 5 0.6 0 Percen t

recover y 100. 0 75. 0 78. 6 80. 4 Percen t o f

clea n coa l
38. 3 28. 5 10. 2 77. 0 Dryin g

cost , $/to n

0.9 0 0.9 0 Cos t o f

preparation , $/to n 0.22 5 0.19 1 0.199 ) 0.256 ) 0.076 ) 0.090 ) 1.03 7 Cos t o f preparation/to n o f clea n coa l = $1,03 7 —0.7 7 = $1.34/to nP.3 3



### portray s coa l fromeaster n Kentuck ymine d b

yconventiona l methods ; Tabl e 3- 4 portray s coa l fro msouther n Wes t Virgini a mine d b ycontinuou s minin g methods .

3-1 6Tabl e 3-4 . ILLUSTRATIVE PREPARATIONCOSTS , WES T VIRGINI ACOAL S Siz e Ra wcoa l f + 1/ 4 in . 1/ 4 x 28 M 28 M x 0 Percen t o f

tota l coa l 100. 0 15. 0 65. 7 19. 3 100. 0 Cost . $/to n

screenin g 0.22 5 washin g

0.37 5 0.5 5 0.6 0 Recover y

100. 0 41. 0 68. 1 69. 1 Percen t o f

clea n coa l
6. 1 44. 7 13. 4 64. 2 Dryin g cost ,

$/to n

0.9 0 0.9 0 Tota l

preparatio n cost , $/to n 0.22 5 0.05 6 0.361 ) 0.402 ) 0.116 ) 0.120 ) 1.28 0 Cos t o f preparation/to n o f clea n coa l = $1.2 8 ^

_0.64 2 = $1.99/to n

### 4. 0 PROCES S DESCRIPTIO N

-S i $



## £ A s i t leave s the mine , coa l varie s widel yi n size , as h

content , moistur e content , an d sulfu r content . Thes e ar e the characteristic s tha t ca n b e controlle d b ypreparation . Size s rang e upwar d t o tha t o f foreign materials , suc h a s a chunk o f roc k tha t ha s falle n fro m the min e roo f o r a meta l tie ; larg e piece s o f coa l fro ma veryhard sea

mar e sometime s included . As hconten t range s fro m3 t o 6 0 percen t a t differen t mines . Mos t o f the as hi s introduce d fro mth e roo f o r bottomo f the min e o r fro mparting s (smal l seam s o f slate ) i n th e coa l seam . Thi s ash , calle d extraneou s ash , i s heavie r than 1.8 0 specifi c gravity . The remaining as hi s inheren t i n th e coal . Th e densit yo f the coa l increase s wit hth e amoun t o f as hpresent . Th e moistur e conten t o f the coa l i s als o o f two types . Th e surfac e moisture , tha t whic hwa s introduce d afte r th e coa l wa s broke n loos e fro mth e seam , i s th e easie r t o remove . Thi s moistur e i s introduce d b yexposur e t o air , we t minin g conditions , rainfal l (i n stockpiles) , an

d wate r sprays . Th e remaining moisture , calle d "bed" , "cellular, " o r "inherent " moisture , ca n b e remove d onl yb ycoking o r

M • 

### 4- 1

### combustion . Thi s moistur e wa s include d durin g formatio n o f the coal . j . Foreig n material s ar e introduce d int o th e coa l during th e mining process , th e mos t commo n bein g roo f bolts , ties , ca r wheels , timber , sho t wires , an d cuttin g bits . Sulfu r i n coa l occur s a s sulfates , organi c sulfur , an d pyrite s (sulfide s o f iron) . Th e sulfate s usuall yar e presen t i n smal l quantitie s an d ar e no t considere d a problem . Organi c sulfu r i s bound molecularl yint o th e coa l an d i s no t remov abl e b ytypica l coa l preparatio n processes . Pyrite s gener all yar e presen t i n th e for mo f module s o r mayb e mor e intimatel ymixe d wit hth e coal . Coa l preparatio n plant s remov e onl ya portio n o f th e pyriti c sulfur ; therefor e th e degre e o f sulfu r reductio n depend s o n th e percentag e o f pyrite s i n th e coal , th e degre e t o whic hthi s i s intimatel y mixe d wit hth e coal , an d exten t o f coa l preparation . Al l th e material s describe d abov e ar e combine d wit hthe coa l t o for

mth e run o f min e (ROM ) feed . Coal , a s referre d t o above , denote s the portio n o f the fee d tha t i s desire d fo r utilization . 4. 1 CAPABILITIE S O F COAL PREPARATION Coa l preparatio n processe s ca n improv e the ROM coa l t o mee t marke t demands , a s limite d b yth e inheren t characteris
tic s o f a give n coal .

4- 2P.3 7



## I I

i 

# I Th e top siz e o f th e ROM ca n b e reduce d t o an ysiz e specified , althoughcontro l o f the varyin g siz e increment s can b e poor , dependen t o n the amoun t o f crushing required . N o practica l technolog yi s know

n fo r increasing th e size s o f coa l a s mined . Al l extraneou s as hca n b e removed . Th e limiting facto r fo r remova l o f th e remainde r i s an economi c one . Th e percentag e o f reject s o f coa l mus t no t reac ha poin t tha t preclude s a profi t o n th e operation . Th e coa l frombette r seam s ca n b e processe d t o a reasonabl e as hconten t wit hfe w rejects . Tha t fro

ma poo r sea

mwil l b e unabl e t o matc hth e as hconten t withou t excessiv e losses . Th e optimu mleve l o f removing th e inheren t as hsometime s depend s upo n the percent ag e o f th e refus e materia l having specifi c gravitie s o f 1. 3 o r lower . Althoug hinheren t moistur e canno t b e changed , the surfac e moistur e ca n b e reduce d t o an yleve l tha t i s economi
call ypracticable . Consideration s includ e the possibilit y o f reexposur e t o moistur e during shipmen t an d subsequen t storag e an

d the fac t tha t intens e therma l drying create s idea l condition s fo r readsorptio n o f moisture . Th e fre e sulfu r i n th e coa l i s subjec t t o remova l onl y b ychemica l treatment , whic hi s no t a coa l preparatio n process , o r b

ycombustion . Th e reaso n tha t th e pyrite s ca n

4- 3

### b e partiall yremove d i n washin g processe s i s tha t theyar e

heav yenought o b e remove d wit hthe ash . Th e processe s ca n remov e onl y3 0 t o 6 0 percen t o f the pyrites , however , becaus e some pyrite s ar e no t broke n fre e o f the coa l an d ar e presen t i n a give n piec e i n a quantit yto o smal l t o increas e it s weigh t enought o b e rejected . Foreig n metal s ca n b e remove d easily . Mos t woo d frag
ment s ca n b e removed , althougha fewsmal l piece s o f woo d caus e n o particula r har mbecaus e the

yar e combustible . 4. 2 APPLICATIONO F CLEANIN G PROCESSE S T O SIZ E INCREMENT S Differen t type s o f mechanica l cleaning apparatu s ar e require d fo r cleaning o f coal s i n differen t siz e ranges . Coa l large r than 8 inche s i s usuall ycrushe d t o a smalle r size ; whe n lum

p coa l i s required , the larg e fractio n i s cleane d b

yslat e pickers . Th e nomina l siz e range s an d th e applicabl e cleaning equipmen t ar e liste d i n Tabl e 4-1 . Tabl e 4-1 . COA

L SIZ E RANGE S FOR CLEANIN G EQUIPMEN

T + 8 8 x 1/ 4 48 M inche s 1/ 4
x 4 8 M

x 0 Picking table s

Heav ymedi a bat ho r drum s Jig s Dieste r table s Heav ymedi a cyclone s Ai r table s Frot hflotatio n Us e o f therma l dryer s i s usuall yrestricte d t o the two smalle r siz e fractions . Occasionall ythe + 1/4-inc hfrac
tio n i s drie d t o permi t screening . 4- 4P.3 9

i I


### 4. 3 COAL SIZIN G Th e firs t operation s performe d o n ROM coa l ar e remova l o f tram p iro n an

d reductio n o f siz e t o permi t mechanica l processing . Th e schemati c o f coa l sizing circui t i s show n in Figur e 4-1 . Th e ROM coa l i s firs t expose d t o a high-intensit y magnet , usuall ysuspende d ove r the incoming bel t conveyor , whic hpull s th e iro n impuritie s ou t o f the coal . Thi s magne t sometime s follow s th e breake r bu t alway s precede s a screen-crusher . Th e coa l the n goe s t o the breaker , whic hi s a larg e cylindrica l shel l wit hinterio r lifting blades ; th e shel l i s perforate d wit hhole s (2
- t o 8-inchdiameter ) t o permi t passag e o f smal l material . Th e breake r rotate s o n a hor
izonta l axis , receiving materia l i n on e end , tumbling i t a s i t passe s through , breaking th e sof t materia l (coal) , whic h passe s throughth e hole s i n th e shell , an d permitting the hard , large , unbroke n materia l t o pas s ou t the rear . Th e smal l materia l (-

4 inches ) goe s t o the cleaning plant , an d the larg e rejecte d materia l fall s int o a bi n t o b e haule d away . Variou s type s o f crusher s ar e availabl e fo r coa l crushing . Th e hammermill , show n i n Figur e 4-2 , an d the rotarybreaker , show n i n Figur e 4-3 , ar e mos t commonl yused . 4- 5P.4 0

CA RDUM P 

## A TRUC K DUM P



## A

AFUGITIVE DUS T

AEMISSIONPOINT S BARG E LOADING 

## A Figur e 4-1 . Coa l sizing circuit .

4- 6P.4 1



### Figur e 4-2 . Hammermill .

Figur e 4-3 . Rotarybreaker ,

4- 7P.4 2



### A n alternat e flowdirect s the ROM coa l t o a scalping screen , fro

mwhic hth e oversiz e materia l ( + 4 inches ) fall s t o a crusher , wher e i t i s reduce d t o - 4 inche s an d i s recombine d wit hthe scree n underflo wfo r transportatio n t o the cleaning plant . Thi s systemi s use d mor e tha n the breake r bu t i s somewha t vulnerabl e t o larg e piece s whic h pas s throughthe crushe r an d mus t b e remove d i n a late r process . Th e crushe r mos t commonl yuse d fo r thi s purpos e i s a heavy-dut ysingl e rol l wit htram p iro n protection . Doubl e roll s ar e mor e difficul t t o maintai n i n thi s heav yservice , ar e mor e expensive , an d offe r n o particula r advantage . Slow-spee d hammermill s o r impactor s ar e mor e difficul t t o maintain , an d ja wcrusher s hav e no t bee n required . Th e rawcoa l i s sometime s stored , prio r t o washing , t o allo woptimu

mscheduling o f min e an d plan t operations . Ope n storag e i s the mos t common ; silo s ar e als o used . A t mine s using uni t trai n shipment , prepare d coa l i s store d t o accumulat e enought o fil l a train . Fo r thi s purpose , silo s ar e use d mos t ofte n t o preven t accumulatio n o f moistur e an

d exposur e t o wind . Some ope n storag e i s als o practiced . A t othe r mines , car s o r barge s ar e loade d directl ya s th e coa l i s processed , received , an d shippe d eac hday .

4- 8P.4 3



# I I

- t 

# I I 4. 4 PNEUMATI C CLEANIN G Pneumati c cleaning devices , o r ai r tables , ar e applie d t o the smal l fraction s (-3/ 8 inches) . I n thes e device s current s o f ai r flowupwar d througha perforate d bottom plat e ove r whic ha laye r o f coa l passes . Th e extrem e fine s ar e entrappe d i n th e ai r an d mus t b e recapture d b ycyclone s an d ba g filter s fo r retur n withou t qualit yimprovement . A s the coa l reache s th e en d o f the tables , the bottomlaye r i s heav y(high-ash ) material , a cente r laye r i s medium-weigh t coa l an d bon e (high-ash) , an d the top laye r i s coa l (low
ash ) . Th e middl e laye r mus t b e incorporate d wit hth e refus e (an d rewashed ) o r wit hthe coal . Atypica l pneumati c cleaning circui t i s show n i n Figur e 4-4 . Th e cross-sec tiona l vie wo f an ai r tabl e i s show n i n Figur e 4-5 . Th e efficienc yo f thes e device s i s poor . Thei r abilit y t o remov e as hi s limite d t o 2 t o 3 percent , regardles s o f ho wmuc hi s present . Thes e device s represen t th e lowes t capita l investmen t o f al l cleaning devices , an d theyentai l no problem s o f wate r suppl yan d disposal . Th e incoming coa l mus t b e screened , and , becaus e fee d t o the table s mus t b e dry , therma l drying o f th e rawfee d i s require d a t some plants . Th e therma l dryers , i n turn , requir e cyclone s an d scrubber s fo r contro l o f particulat e emissions . Therma l dryer s ar e fire d wit hcoal , oil , o r gas .

4- 9P.4 4

2 X3/ 8 •*

•

RA W 2 X0 

## A ,

SURG E BI N

YEN T T O ATMOSPHER E PRIMAR

YAI R T OLOADIN GO RWE T CLEANING 32 5 M X0 B VEN T T O

*" ATMOSPHER E SCRUBBE R

» 2 X0 . 

## H 

## G 3 

## - - :

COMBUST . AI R ^^MBUS 1 

# 2 i COMBUST . CHAMBER DRYIN

G CHAMBER ] 10 0 M

X0 

# Y _ SLURRYTO POND S

1/ 4 X32 5 M CYCLON E BA G.--- _ FILTER W W

I • r' 3/ 8 X0 3/ 8 X0 

## A J : CYCLON

E

2 X325 M - A —* 1 SCREE

N fc^g^ 2 X3/8

m C M e o x 0 0 •» . C O 

# c AI RTABL E

A EMISSION

POINT S B STAC KEMISSION S 

# ^ 7 REFUS E BI N
Figur e 4-4 . Pneumati c cleanin g circuit .

4-1 0P.4 5



## NV^i'B^^FEE D V VvH V

CLEA N COA L MOTO R SHAKE R UNI T SPEE D REDUCE R

REFUS E FLUTTE F

VALV E HUTC H 

### Figur e 4-5 . Ai r

table .

4-1 14. 5 JIG-TABL E WASHIN G Jig-tabl e washin g plant s ar e thu s name d becaus e jig s ar e use d t o clea n th e +l/4-inc hincremen t and Dieste r table s t o clea n th e 1/ 4 inc hx 28 M increment . Frot hcell s and/o r therma l dryer s ma yb e use d i n conjunctio n wit hthi s equip
ment . Figur e 4- 6 show s a coa l cleanin g circui t wit hji g table . Th e air-pulsate d coa l ji g i s show n i n Figur e 4-7 , th e Deiste r coa l washin g tabl e i s show n i n Figur e 4-8 . Th e ra wcoal , restricte d t o size s smalle r tha n 8 inches , i s separate d o n a we t scree n (usuall y1/4-inc h mesh) . Th e large-size d incremen t goe s int o th e jig ; th e remainin g coa l i s sen t t o a separat e cleanin g circuit . Th e coa l i s dewatere d o n screen s an d i n centrifuges , crushe d t o th e desire d size , an d loaded . Th e ji g make s th e "equivalent " gravit yseparatio n o n th e principle s o f settlin g i n risin g an d fallin g currents . Th e small-size d coa l (-1/ 4 inch ) i s combine d wit hth e prope r amoun t o f wate r an d distribute d t o th e tables , wher e th e refus e i s separate d fro mth e coal . Th e refus e i s dewatere d o n a scree n an d discarded . Th e clea n coa l i s dewatere d o n a siev e ben d ( a stationar y gravit yscreen) , wher e th e extrem e fine s ar e remove d an d discharge d int o a centrifug e fo r fina l dewaterin g an d remova l o f th e fines . Th e clea n coa l (+28M ) i s the n loade d o r conveye d t o a therma l dryer . Th e Dieste r tabl e i s a

4-1 2P.4 7

SCREE N f REFUS E 4X 0

co C M RA

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X1/ 4 ~~* } SCREE

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1/ 4 X28M\ ^ S TM)

SCREE N
28 M X0 1/ 4 X28 M 28 MX 

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# V REFUS E BI N ( .1/ 4 X28 M CENTRIFUG E \ X 28 M 

## A W CRUSHER 1 1 1/ 2 X 1/ 4 CYCLONE , H

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IO M• r- J 28 MX 200 M 1/ 4 X 200 M

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### Figur e 4-6 . Ji g tabl e cleanin g circuit .

4-1 3P.4 8 

## A"^ ! /'- S ft-.

Figur e 4-7 . Air-pulsate d Dig ,

Figur e 4-8 . Deiste r table .

4-1 4P.4 9



# 1 | 1 ' I flat , "riffled " surface , approximatel y1 2 fee t square , whic h

oscillate s perpendicula r t o the "riffles, " i n th e directio n o f th e flowo f coal . Th e heav yreject s ar e discharge d of f on e en d o f th e discharg e sid e o f the table , the ligh t coa l i s discharge d fro

m th e opposit e end , an d th e "middlings " ar e distribute d between . Th e slurryproduced , along wit hth e fines , require s clarificatio n befor e recirculatio n i s feasible . Clari
ficatio n i s describe d i n Sectio n 4. 7 an d portraye d i n Figur e 4-11 . 4. 6 HEAVY-MEDI AWASHIN G PLANT I n a heavy-medi a washin g plant , al l the cleanin g i s don e b yflotatio n i n a mediu mo f selecte d specifi c gravity , maintaine d b

ya dispersio n o f finel yground magnetit e i n water . Th e plan t i s depicte d i n Figur e 4-9 . Aschemati c o f a typica l heavy-medi a cyclon e i s show n i n Figur e 4-10 . Th e incoming ra wcoa l i s separate d a t 1/ 4 inc ho n a n incline d screen . Th e "overs " procee d t o a fla t "prewet " screen , wher e the fin e dus t particle s ar e spraye d of f fro m th e +1/4-inc hcoal . Thi s incremen t i s discharge d int o a heavy-mediu

mvesse l o r bath , wher e the refus e i s separate d fro mthe coal . Th e refus e i s discharge d t o a "refus e rinse " screen , wher e i t i s dewatered . Th e free d mediu m i s divide d int o two parts , on e returning directl yt o circulatio n vi a the heavy-mediu

m sum p an d th e othe r pumpe d t o magnetit e
4-1 5P.5 0

4 X1/ 4

11/2X 0

T O REFUS E BI N ( A 

# \l ( D ( E ( F 

# i s ( I RA WCOAL SCREE N PR E WE T SCREE N LOADINGOR STORAG E (0 ) COARS E MAG . SEPAR . CLEA NCOA L (K ) FIN E MAG . SEPAR . A (L ) CENTRIFUG E REF . RINS E SCREE N(M ) CENTRIFUG E COAL RINS E SCREE N(N ) CENTRIFUG E SLURRY SCREE N(P ) CRUSHE R REFUS E RINS E SCREE N(R ) CYCLON E SIEVE BEND (S ) LIGH T MEDI ASUM P HVY . MEDI ABAT H (T ) HEAV Y MEDI ASUM P HVY . MEDI ACYCLON E (V ) HEAV Y MEDI ASUM P AEMISSIONPOINT S (1 ) T O WATE R CLARIFICATIO N Figur e 4-9 . Heavy-medi a cleanin g circuit . 4-1 6P.5 1 

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### recovery . Th e refus e i s discharge d fro mth e scree n fo r disposal . Th e coa l i s discharge d fro mth e washe r t o a coal
rins e screen , wher e th e coa l i s dewatere d an d th e mediu

mi s treate d a s fromth e refus e screen . Th e clea n coa l i s the n centrifuged , crushed , an d loaded . Th e fin e coa l (-1/ 4 inch ) fro m th e rawcoa l screen s i s combine d wit hmagnetit e an d wate r an

d pumpe d t o a heavy-medi a cyclone , wher e th e refus e i s separate d fromth e coa l b ycycloni c action . Th e mediu m fo r thi s us e i s differen t fromth e on e use d i n th e heavy
medi a vesse l i n tha t the magnetit e i s fine r an d th e effec
tiv e specifi c gravit yi s different . Th e refus e i s dewatere d an d th e mediu

mi s recovered , a s i n th e coars e coa l section . Th e coa l i s discharge d ove r a siev e bend an d the n proceed s t o a centrifug e fo r fina l dewaterin g prio r t o transfe r t o a therma l drye r o r t o loading . Becaus e th e magnetit e recovere d fromth e rins e screen s i s dilute d b

ysprays , i t i s processe d i n magneti c separator s fo r recoveryo f th e soli d mineral . Eac hwashe r (bathan d cyclone ) retain s it s ow n recoverysystem , whic hinclude s sumps , pumps , an

d magneti c separators . Th e separato r i s a shaft-mounte d stee l dru mcontaining an interio r fixe d magnet . Th e cylinde r rotate s withi n a vesse l containin g coa l slurryan

d magnetite , retrieving soli d magnetit e from th e slurryb

yvirtu e o f th e magneti c qualitie s o f th e magnetit e an

d th e magneti c fiel d withi n th e drum .

4-1 8 

## . 4P.53 _

) \ 

### Th e effluen t fromth e centrifuge s contain s -28 M coal , broke n fromlarge r piece s o f clea n coal . Thi s materia l i s thickene d i n a cyclone , deslime d o n a screen , an d centri
fuged prio r t o loading . 4. 7 WATE R CLARIFICATIONPLANT Th e wate r clarificatio n plan t receive s al l th e slurry fro mth e washin g plant , separate s the 4 8M x 0 fractio n fo r cleaning , an

d return s the wate r fo r reuse . Atypica l clarificatio n plan t i s show n i n Figur e 4-11 . Th e 48 M x 0 fractio n flow s t o frot hflotatio n cells , wher e i t i s mixe d thoroughl ywit ha reagen t (light oil) . Th e coa l accept s a coating o f oi l an

d float s of f the to p o f the liqui d t o a dis c filter , wher e th e exces s wate r i s draw n througha fabri c b

ya vacuum . Th e wate r i s recirculate d t o the washery , an

d th e fin e coa l i s transporte d t o loading o r t o a dryer . Figur e 4-1 2 show s th e frot hflotatio n unit . Th e refus e doe s no t accep t th e oi l coating an d sinks , t o b e remove d wit hmos t o f the incoming wate r t o a stati c thickener . Th e thickene r i s a large , circular , ope n tank , whic hretain s the wate r long enought o permi t the particle s o f refus e t o sin

k t o the bottom . Clarifie d wate r i s remove d fro mth e surfac e b

y"skimming troughs " aroun d the perimete r o f the tan

k an d i s recirculate d t o the cleaning plant . Th e tan k i s equippe d wit ha rotating rake , whic hrake s the fin e refus e fro m the bottomo f the tan k t o the cente r o f
4-1 9P.5 4

28 M X0 48 M

X0 RA W COAL SLURRY
4 8 X28M ^ RETUR

N T O • • (CYCLONE 

# 1 f 'DO ' REFUS E

WASHINGCIRCUI T CLEA N FLOTATIO N

CELL S COAL

DIS C FILTE R

CHA M CM L CLARIFIE DWATE R RETURN TO THERMA

L RETURN

T O DRYE RO RLOADINGCIRCUI T 

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### Figur e 4-11 . Wate r clarificatio ncircuit .

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FEE DBO X INTERMEDIAT E BOX DIREC T CONNECTIO N

Figur e 4-12 . Frot hflotatio n unit .I I • 

### th e tank , wher e i t i s collecte d b ya pum p an d transferre d t o a dis c filter . Th e filte r remove s par t o f th e wate r fo r recirculatio n an

d discharge s the solid s a s refuse . 4. 8 THERMAL DRYIN

G Th e clea n coa l fro

mvariou s we t cleaning processe s i s we t an d require s drying t o mak e i t suitabl e fo r transpor tatio n an

d fina l consumption . Therma l drying i s employe d t o dr ythe we t coal . Drying i n th e therma l drye r i s achieve d b ya direc t contac t betwee n th e we t coa l an d current s o f ho t combustio n gases . Variou s dryer s markete d b ydifferen t manufacturer s wor k o n the same basi c principle . Th e mos t commo n type s o f dryer s ar e show n i n Figure s 4-1 3 through4-16 . Th e fluid-be d drye r i s show n i n Figur e 4-13 . Th e drye r operate s unde r negativ e pressur e i n whic hdrying gase s ar e draw n fro mthe hea t sourc e througha fluidizing chamber . Drye r an

d furnac e temperatur e controller s ar e employe d i n the contro l systemt o readjus t th e hea t inpu t t o matc hth e evaporativ e load changes . Th e multilouve r dryer , show n i n Figur e 4-1 4 i s suitabl e fo r larg e volume s an d fo r the coal s requiring rapi d drying . Th e coa l i s carrie d u p i n the flight s an d the n flow s down
war d i n a shallo wbe d ove r th e ascending flights . I t gradu
4-2 2P.5 7

FA NSTAC K .FA N

DUS T COLLECTO R

DUS T BIN- V DUS T SCRE WCONVEYOR SETTLINGCHAMBE R DISCHARG E VALVE AUTOMATICALL Y CONTROLLE D FEE D AND DISCHARG E GATE S ROL L FEEDE R

' TEMPERINGAI R DAMPE R FURNAC E
BY-PAS S STAC K



### i Tabl e 4-13 . Fluid-be d dryer .

4-2 3P.5 8

Figur e 4-14 . Multilouve r dryer ,

Figur e 4-15 . Cascad e dryer .


# t; 4-2 4P.5 9

ALTERNAT E VEN T

WE T SCRUBBE R (I F REQUIRED ) C- E RAYMON D FLAS H DRYIN G

ALTERNAT E ARRANGEMEN T FOR VER Y FIN E WE T COA L

DRY COA L DISCHARG E FRO MAI R LOCK^ ^ AUTOMATIC—2/T l DR Y DIVIDE R M u DR Y RETURN WE T FEE D MIXE R -DRYIN GCOLUMN DR Y COA L CONVEYO R -WE T FEE D CONVEYO R WE T FEE D BI N -GAT E WE T FEEDE R

-DOUBL E FLA P VALV E TEMPERIN G AI R DAMPE R 

### Figur e4-16 . Flas hdryer .

4-2 5P.6 0

all ymove s acros s th e dryer , a littl e a t eac hpass , fro mth e fee d poin t t o th e discharg e point . Th e cascad e drye r i s show n i n Figur e 4-15 . Th e we t coa l i s fe d t o th e drye r b ya rotar yfeeder ; a s th e shelve s i n th e drye r vibrate , th e coa l cascade s dow n throug hthe m an d i s collecte d i n a conveyo r a t th e botto mfo r evacuation . Ho t gase s ar e draw n upwar d throug han d betwee n th e wedg e wir e shelves . Th e flas hdrye r i s show n i n Figur e 4-16 . Th e ter m "flash " i s derive d fro mth e fac t tha t th e we t coa l i s continuousl yintroduce d int o a colum n o f high-temperatur e gase s an d moistur e remova l i s practicall yinstantaneous . 4. 9 EMISSIO NSOURCE S AN D CONTRO L DEVICE S Al l emissio n source s ar e subjec t t o opacit yregulation s an d tw o ar e subjec t t o particulat e coun t regulations . Th e pneumati c cleanin g plant s generat e emission s fro mth e ai r table s an d ar e subjec t t o on e standard ; therma l dryer s hav e a n emissio n stac k and ar e subjec t t o anothe r standard . Emissio n point s i n th e variou s plan t section s ar e shown i n th e appropriat e diagrams . Th e mos t commonl yuse d contro l device s fo r eac hemissio n poin t ar e keye d a s follows : (1 ) Cyclon e (2 ) Scrubbe r (3 ) Spra y (4 ) Baghous e o r fabri c filte r (5 ) Enclosur e 4-2 6P.6 1

Thes e parenthetica l number s ar e use d i n th e followin g tabulatio n relatin g emissio n source s an d thei r controls . Coa l Handlin g Facilitie s R R an d min e ca r dump s - 2,3, 5 Truc k dump s - 2,3, 5 Storag e bin s an d silo s - 4, 5 Breaker s an d crusher s - 3,4, 5 Conveyo r transfe r point s - 3,4, 5 Screen s - 4, 5 Trucks , R R car , an d barg e loadin g station s - 1/4, 5 Pneumati c Cleanin g Plan t Surg e bi n -4, 5 Therma l drye r stac k (i f present ) - 1, 2 Vibratin g screen s - 4, 5 Ai r table s 1,4, 5 Crushe r - 3,4, 5 Jig-Tabl e Washin g Plan t Scree n - 4, 5 Loadin g facilit y- 2,3, 5 Therma l drye r (i f present ) - 1, 2 Heavy-Medi a Washin g Plan t Scree n - 4, 5 Loadin g facilit y- 2,3, 5 Therma l drye r (i f present ) - 1, 2 4.1 0 CONTRO L DEVICES , THEI R CAPABILITIE S AN D EFFICIENCIE S Th e variou s contro l device s ar e employe d singl yo r i n combinatio n a t eac hemissio n poin t accordin g t o th e tem perature s an d volume s o f flu e gases , th e degre e o f contam ination , and th e applicabl e regulations . Cyclon e size s rang e fro m2 inche s t o 1 8 fee t i n diameter , th e smalle r bein g applie d i n group s tha t us e a commo n inle t
4-2 7

### P.6 2

an d dus t hopper . Acyclon e serve s a s a primaryseparato r becaus e it s efficienc yi s limite d t o particle s large r than 4 4 microns . Th e efficienc yi s a functio n o f th e particl e mass , inle t velocity , an d th e radiu s o f th e cyclone , in
creasin g wit hsmalle r radi i an d highe r inle t velocities . Pressur e dro p als o increase s wit hvelocity . Some variable s o f cyclon e desig n ar e indicate d i n Tabl e 4-2 .

Min . Max . Cyc . dia . 2 in . 1 8 ft . Tabl e 4- 2

Capacity , cf m 1 0 25,00 0 . CYCLONE

Inle t velocity , fp s 1 5 7 5 VARIABLE S
Pressur e drop , in . 0. 5 6. 0 Smalles t

siz e collecte d (§50 % eff. , \i 1 0 20 0 Cyclone s ar e line d wit hrefractorie s o r water-jackete d fo r processing o f ho t gase s an d ar e fabricate d o f alloy steel s fo r processin g o f corrosiv e gases . Scrubber s ar e enclosure s i n whic hdus t particle s ar e agglomerate d i n smal l drop s o f water , whic hthe n flowfrom th e vessel . I n impingement-typ e scrubbers , agglomeratio n i s accomplishe d b

ydriving th e dust-lade n ga s a t highveloc
itie s ont o floode d targets . We t centrifuga l separator s pas s th e dust-lade n ai r througha zon e o f high-velocit ywate r droplets . We t dynami c precipitator s caus e th e dus t t o

I. i 

### 4-2 8

### P.6 3

imping e o n wette d fa n blades . Aventur i scrubbe r acceler
ate s th e dust-lade n ai r througha ventur i throat , wher e i t atomize s the wate r t o for mdroplets . Scrubber s los e efficienc yrapidl yi n collectin g par ticle s belo w5 microns . Efficienc ylos s i s proportiona l t o the pressur e dro p o r powe r consumption . Th e majo r scrubbe r variable s ar e presente d i n Tabl e 4-3 .

Scrubbe r typ e Impingemen t Centrifuga l Dynami c Ventur i Tabl e 4-3 .

Wate r consumptio n pe r 1,00 0 cf m gas , gpm 3- 5 4-1 0 1 3-1 5 SCRUBBE R

Pressur e drop , in . 6- 8 2- 6 1 12-6 0 VARIABLE S

Capacity , cf m 90,00 0 140,00 0 25,000 a 

### 140,00 0 Max .

efficiency , % (Particl e siz e range ) 9 5 (1- 5 micron ) 9 0 (2- 5 micron ) 95 a 

### (2- 5 micron ) 9 8 (submicron ) Estimate d Scrubber s ar e use d fo r contro l o f therma l drye r emis
sion s becaus e theyca n accommodat e ga s temperature s u p t o 250° F an

d ar e insensitiv e t o th e heav ymoistur e content . Orific e meter s ar e commonl yuse d fo r measurin g the scrubbe r wate r flowrates .

4-2 9

### £.6 4

Tabl e 4- 4 present s the flowrat e variable s fo r si x commo n orific e sizes .

Pressur e lb/in 2 

### 2 0 3 0 4 0 5 0 6 0 Tabl e 4- 4

3/1 6 3. 0 3. 6 4. 1 4. 6 5. 1 . ORIFIC E FLO W

Wate r flow , gpm diamete r o f orific e 1/ 4 5. 2 6. 4 7. 4 8. 2 9. 0 5/1 6

8. 1 10. 0 11. 5 12. 8 14. 0 3/ 8

11. 7 14. 4 16. 5 18. 5 20. 2 RATE S

, in . 7/1 6 15. 8 19. 5 22. 4 25. 0 27. 5 1/ 2

20. 1 25. 4 29. 4 32. 9 36. 0 Baghouse s o r fabri c filter s ar e applicabl e fo r captur e o f fin e particle s o f dus t whe n th e gase s ar e a t moderat e temperatures , contai n n o stick ymaterials , an

d ar e nonex plosive . Th e dust-lade n strea mi s passe d througha finel ywove n o r felte d fabri c o n whic ha laye r o f dus t serve s a s the filtering medium . A s thi s dus t laye r thickens , the ba g i s "shaken " mechanicall yo r b yabrup t pressur e change s t o remov e a portio n o f the filte r cake . Th e filte r i s usuall yi n th e shap e o f a circula r closed-end cylinde r 5 t o 1 2 inche s i n diamete r an d u p t o 3 0 fee t long . Smalle r filter s ar e use d t o contro l emission s frombi n an

d sil o openings . Th e siz e o f a filte r instal
latio n depend s o n th e amoun t o f ai r an d dus t t o b e filtere d

4-3 0

### P.6 5

Th e rati o o f ai r t o filte r clot hare a depend s o n severa l variables ; differen t service s requir e differen t ratio s o r filtering velocities . Th e guideline s use d fo r filtering o f coa l dust s ar e ratio s o f 6/ 1 fo r highdus t loading s an d elevate d temperatures , progressin g up t o 8/ 1 fo r genera l dus t loadings . Pressur e differential s rang e fro m2 t o 1 0 inche s w.g . Fabric s ar e selecte d o n a basi s o f chemica l resistance , tensil e strength , temperatur e resistance , weave , an d elec
trostati c characteristics . Operatin g temperature s o f some commo n fabric s ar e show n i n Tabl e 4-5 .

Cotto n Woo l Dacro n Glas s Nylo n Orio n Tabl e 4-5 . OPERATIN G TEMPERATURE S Maximu moperating temperature , ° F Lon g term 16 0 20 0 27 5 50 0 20 0 24 0 Shor t ter m 20 0 25 0 30 0 65 0 25 0 29 0 Th e mechanism s fo r cleanin g th e bag s includ e han d shaking , revers e ai r jets , mechanica l rappers , an d ba g shakers . Sinc e a ba g i s ou t o f servic e whil e i t i s being cleaned , th e installatio n mus t b e designe d t o accommodat e

4-3 1

### P.6 6

thi s los s o f service . Th e bag s ar e fastene d a t the top , wit hquick-releas e fastening s t o permi t eas yba g replace
ment , an

d ar e suspende d i n th e dust yenvironment . Avacuu m i s introduce d i n the bag , pulling th e ai r throughth e fabri c ba g fo r releas e throughth e top , leaving the dus t collecte d o n th e exterio r o f the bags . I n some installation s th e dust yai r flow s throughth e interio r o f th e bag . Th e baghous e containin g th e fabri c filter s mayb e square , rectangular , o r circula r an d i s constructe d o f metal . Th e vertica l dimensio n exceed s th e lengt ho f th e bags , an

d the to p o r roo f i s flat . Th e ope n bottom i s connecte d t o a conica l o r pyramida l section , whic hreceive s th e dus t shake n fromth e bag s fo r remova l b ya n airloc k feede r valve . Th e baghous e i s sel f supporting , wit hsuit
abl e walkway s fo r access .

4-3 2

### P.6 7

5. 0 INSTRUMENTATIONAN D RECORD S Instrumentatio n fo r measuremen t o f proces s parameter s an d method s o f recordin g thes e measurement s ar e importan t i n controllin g an

d predicting proces s emissions . Th e accurac y o f predictin g emission s ca n b e directl yrelate d t o the degre e o f sophisticatio n o f th e instrumentatio n an d record
keepin g a t th e plant . Th e instrumen t reading provide s an instantaneou s indicatio n o f operatin g conditions ; detaile d record s wil l provid e a basi s fo r reviewin g plan t operation s ove r a n extende d period . Th e flo wo f coa l throughth e preparatio n equipmen t i s a constan t functio n o f th e amoun t o f coa l inpu t a t th e feede r conveyor . Overloadin g o f th e feede r conveyo r wil l resul t i n overloadin g o f th e equipmen t following it . Mos t o f th e equipmen t incorporate s an indicato r showing instantaneousl y th e load bein g processed . I n olde r plant s mos t equipmen t contro l i s o f th e ON-OF F type . I n cas e o f overloading , a re d ligh t come s o n an d th e equipmen t i s automaticall ystopped . Thes e ON-OF F light s d o no t indicat e i n advanc e a potentia l malfunctio n o r overloa d an d ar e no t helpfu l fo r indicatio n o f emissions .

5- 1

### P.6 8

Th e newe r an

d large r plant s generall yincorporat e a centra l contro l roomwit hautomate d instrumentatio n showing th e instantanou s loading an d othe r majo r parameter s suc ha s pressur e dro p an

d temperatur e o f th e gases . Th e monitoring record s o f require d proces s parameter s ar e als o maintaine d i n thi s centra l contro l room . Whe n th e instrument s indicat e abnorma l operatin g conditions , th e operato r ca n tak e actio n t o preven t possibl e majo r equipmen t malfunctio n o r plan t shutdown . Th e us e o f instrumen t reading s fo r predicting plan t emission s i s discusse d i n Sectio n 8.0 . 5. 1 PROCES S INSTRUMENTATION Instrumentatio n i n th e coa l preparatio n plan t i s relativel ysimpl e i n compariso n wit hinstrumentatio n a t othe r proces s industries . Th e instrument s generall yfoun d o n coa l preparatio n equipmen t ar e describe d below : Conveyo r Th e conveyor s ar e drive n b yelectri c motors ; th e curren t draw

n b yth e conveyo r motor s varie s directl ywit h th e conveyo r load . Th e ammeter s locate d i n th e contro l room indicat e th e instantaneou s curren t draw n b yth e conveyo r motors . Whe n excessiv e curren t i s indicated , conveyo r an d equipmen t loading shoul d b e investigated .

5- 2

### P.6 9

Some conveyor s ar e als o equippe d wit hload meters . Thes e meter s indicat e th e percen t o f rate d load carrie d b y th e conveyo r a t a particula r instant . Ammeter s and load meter s giv e basicall ysimila r indications . Crusher s Th e crushe r load i s directl yproportiona l t o th e fee d rat e an d fee d sizes . Th e crushe r i s drive n b yan electri c motor . Th e ammete r fo r th e moto r i s generall ylocate d i n the centra l contro l room . Indicatio n o f excessiv e curren t shoul d b e investigate d t o determin e the cause . Screen s I n additio n t o th e load-curren t ammeters , th e screen s mayb e equippe d wit hpressur e gauge s indicating th e pressur e o f wate r t o th e sprays . Th e variou s correc t combination s o f load curren t an

d spraypressur e shoul d b e establishe d durin g performanc e test s fo r referenc e during periodi c inspections . Th e increas e i n load cbrren t woul d mea n increase d scree n loading ; thi s shoul d b e matche d b yincrease d spra

ywater , whic hwil l b e indicate d b yth e pressur e gauge . Ai r Table s I n general , th e ne wai r tabl e installation s wil l b e equippe d wit hinstrument s t o indicat e th e load current , pressur e dro p acros s th e ai r table , an d pressur e dro p acros s the contro l equipment . Th e load curren t i s indicate d b yth e

5- 3

### P.7 0

ammeter ; pressur e drop s ar e indicate d b yth e pressur e gauges . Thes e instrument s can b e locate d i n a centra l contro l room . Th e correc t combination s o f thes e parameter s shoul d b e establishe d durin g performanc e test s fo r futur e reference . An excessiv e pressur e dro p acros s th e ai r tabl e mean s a highe r percentag e o f fin e coa l i n th e tabl e feed . Thi s wil l als o resul t i n a n increase d load o n th e contro l device . Th e pressur e dro p acros s th e contro l devic e shoul d b e matche d t o mee t th e increase d particulat e loading . Therma l Dryer s Therma l dryer s ar e equippe d wit hinstrument s t o in
dicat e th e fee d rat e and exi t ga s temperature . Th e exi t ga s temperatur e i s continuousl yrecorde d an d monitored . I n th e cas e o f therma l dryer s wit hventur i scrubbers , scrubbe r wate r suppl ypressur e an d pressur e los s i n th e ventur i constrictio n ar e als o continuousl ymonitored . Th e monitoring aspect s ar e discusse d unde r record s i n Sectio n 5.2 . Th e therma l drye r fee d rat e indicate s th e quantitativ e loading ; however , thi s mayno t b e usefu l fo r predicting the emissions . Emission s fromth e therma l drye r woul d depend o n th e moistur e an

d fine-coa l percentag e o f th e feed .

5- 4P.7 1

5. 2 RECORD S Th e NSP S requir e th e continuou s monitorin g o f th e flu e ga s temperatur e a t th e exi t o f th e therma l dryer , pressur e o f th e wate r suppl yt o th e ventur i scrubber , an d pressur e los s i n th e venturi constriction , Arecor d o f thes e parameter s wil l b e availabl e a t th e plan t fo r inspection . Othe r records , thoug hno t require d unde r NSPS , showin g th e plan t fee d rate s an d equipmen t malfunctio n an d shutdow n shoul d b e inspecte d t o determin e th e plant' s emission s betwee n inspections .

i ii . 

### 5- 5

### P.7 2 \A

6. 0 START-UP , SHUTDOWN , AN D MALFUNCTION S Emission s tha t occu r durin g norma l plan t start-up s an d shutdown s ar e exempte d b yregulations . Th e following section s discus s th e possibl e cause s o f extende d emissio n upset s an

d precautionarymeasure s fo r preventin g them . Th e primaryemissio n source s ar e th e ai r tabl e an d the therma l dryer , and , i n some case s o f malfunction , thei r contro l devices . Th e secondaryemissio n source s ar e mor e numerous , les s susceptibl e t o upset , an d mor e easil ycorrected . Thes e source s ar e screens , breakers , crushers , conveyo r transfe r points , storag e bins , loading an d unloading stations , an d supporting equipment . I n thi s section , a brie f discussio n o f emisssio n during plan t start-u

p an d shutdow

n i s followe d b

yanalysi s o f malfunction s tha t ca n occu r i n regula r plan t operation . 6. 1 START-U P AN

D SHUTDOW

N Anorma l interruptio n during a shift , suc ha s tha t cause d b

yca r changes , lac k o f coal , o r mechanica l failur e o f equipment , usuall ydoe s no t caus e a n emissio n upse t becaus e the plan t i s kep t running . Th e hea t o f the therma l drye r i s regulated , an d the othe r emissio n source s wil l

6- 1

### P.7 3

receiv e n o coa l t o create , dust . Upo n resumptio n o f coa l flow , th e firs t coa l encounter s norma l conditions . I n start-u

p a t th e beginnin g o f a shif t o r afte r a long breakdown , th e perio d o f adjustmen t i s short , lastin g onl y unti l th e flo wo f coa l throughth e plan t i s complete . I n the starting sequence , eac huni t (or several ) i s brough t on lin e a t a time interval . Th e norma l procedure , o n automati c starting , woul d energiz e al l wate r pumps , ai r compressors , an d relate d dus t contro l equipmen t befor e coa l i s received . Th e therma l drye r shoul d b e up t o temperature , and al l spray s shoul d b e operational . A t a well-designe d plant , thi s sequenc e i s interlocked , withou t recours e t o bypass . Som e plant s ar e buil t wit hselecte d interlocks ; thes e arrangement s permi t utilizatio n o f onl ycertai n section s o f the plan t o r operatio n aroun d nonfunctiona l equipment . Manua l control s t o allo wbypassin g o f interlock s ar e common . Imprope r us e o f bypas s feature s i s the mos t probabl e reaso n fo r an emissio n upse t during start-u p o f a plan t wit hinter
locks . Th e shutdow

n procedur e fo r some plant s i s automaticall y execute d i n th e revers e o f start-up , wit hsome variations . Thi s permit s the plan t t o "empty " itself ; mor e commonly , th e "stop " sequenc e i s time d t o a shorte r perio d than is
- re quire d fo r travers e o f th e proces s circuit . I n eithe r

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### P.7 4

event , th e dus t contro l equipmen t shoul d b e time d t o con tinu e operatio n afte r th e coa l fee d i s stopped , fo r a perio d long enought o allo wth e equipmen t t o ru n clean . Th e coa l preparatio n incorporate s an emergenc y"stop " butto n whic hhalt s al l equipmen t instantly . Thi s procedur e entail s n o particula r il l effects , sinc e everything (including th e therma l dryer ) stop s operating . However , i f the incoming coa l i s nea r the capacit yo f th e circuit s an d a buildu

p o f dus t ha s occurre d i n critica l spots , a shor t emissio n upse t mayoccu r o n start-up . 6. 2 CHANGE S I NCOAL FEE D Analysi s o f the incoming coa l maychang e sufficientl y t o creat e plan t emissio n upsets . Thi s i s mos t likel yt o occu r a t a centra l preparatio n plan t tha t processe s coa l fromsevera l mine s an d differen t coa l seams . Th e secon d mos t vulnerabl e plan t i s on e tha t serve s a larg e min e producin g from

bot hconventiona l an d continuou s minin g sections , th e conventiona l typ e producing fine r coal . Variabl e fee d als o ca n prevai l a t a plan t receivin g coa l froma stripping operatio n wit hauge r production . Blendin g th e rawcoal , eithe r frommultipl e storag e unit s o r b

yproportione d acceptance , wil l reduc e the impact s o f variabl e feed . Multipl e storag e facilities , however , ar e rar e an d veryexpensive ; proportiona l fee d i s difficul t an d

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### P.7 5

' i 

### les s positiv e a s a control . Us e o f a singl e rawcoa l

storag e sil o ca n produc e th e same problema t intervals , a s ca n change s i n surfac e moistur e conten t cause d b ydifferen t level s o f spraying underground , we t mines , precipitatio n o n ope n storag e piles , an d exposur e during transport . I n th e discussion s tha t follow , i t i s importan t t o remembe r tha t malfunction s occurrin g a t man ypoint s i n the coa l preparatio n circui t mayb e attributable , a t leas t i n part , t o change s i n coa l feed . 6. 3 MALFUNCTIONO F SUPPORT EQUIPMENT Malfunction s o f supporting equipment , usuall ymechanica l failure , ca n caus e frequen t o r sustaine d interruption s o f plan t operations . Th e mos t usua l ar e liste d below . Breakdow

n o f conveyo r drives , crushers , chains , centri
fuges , feeders , pumps , o r scree n cloths . Blockag e i n bin s o r releas e o f veil-chain s o r plate s int o th e coa l flow . Failur e o f magneti c protectiv e equipment , permittin g introductio n o f larg e "tramp " iro n int o th e feed . Electrica l accidents , inadequat e powe r source , o r inadequat e lightning protection . Poorl ycontrolle d spraying , producin g variabl e moistur e conten t (at drycleaning plants) . Damag e o f ROM conveyo r bel t fromtram p iron , misalign
ment , o r oversize d rock .

6- 4_P,7 6

6. 4 MALFUNCTION S I NSOURCE S O F FUGITIV E DUS T Malfunction s i n dust-producin g equipmen t ar e cause d by overload , poo r maintenanc e o r design , electrica l failure , accident , o r imprope r operation . Ai r Tabl e Th e ai r tabl e i s mos t adversel yaffecte d bya shar p chang e i n siz e distributio n o f th e incomin g coa l t o includ e greate r amount s o f extrem e fines . Thi s shif t permit s over loadin g o f th e dus t contro l equipment . Simpl e overloadin g o f th e ai r table , whic hproduce s a simila r condition , i s cause d bymalfunctio n o f th e proportionin g feede r o n th e ai r tabl e o r bydesir e o f th e operato r t o increas e production . Ai r seal s o n th e table , i f no t properl ymaintained , wil l becom e seriou s source s o f fugitiv e dus t emissions . Therma l Drye r Th e therma l dryer , lik e th e ai r table , i s subjec t t o particulat e emissio n standards . Overheatin g o f a therma l drye r ma yb e cause d byfailur e o f a regulatin g valv e (ga s o r oi l fired ) o r othe r contro l an d usuall ywil l produc e a n "upset " plume . Th e "internals " o f dryer s involv e mechanica l (sometime s moving ) parts , whic h ar e subjec t t o wea r an d damage . Th e refractor ylinin g als o i s subjec t t o wea r and damag e an d i s subjec t t o schedule d replacement .


### 6- 5

### P.7 7

Th e secon

d sectio n o f a therma l drye r i s a large
diamete r cyclone , use d t o extrac t th e particulat e matte r large r than 30 0 M fro mthe ga s stream . Thi s cyclon e ha s n o interna l workin g parts , bu t the refractorylining i s subjec t t o wear . Volum e o f air , temperature , an d pressur e dro p ar e th e chie f criteri a fo r satisfactoryo r norma l cyclon e operation . Othe r cause s o f emission s ar e mechanica l failur e o f the discharg e feede r an d wearin g o f seals . Th e las t sectio n o f a therma l drye r i s a scrubber , use d t o remov e the fin e portio n o f coa l (30 0 M x 0 ) fro m the ai r stream . Th e scrubbe r mayincorporat e a bypas s fo r emergenc y use , whic hmayb e partiall yope n an d permi t particulat e emission . Th e inspecto r shoul d examin e th e bypas s durin g eac hplan t inspectio n an d shoul d als o examin e record s o f bypas s use . Th e ventur i scrubbe r i s th e typ e mos t commonl yused . It s efficienc yi s a functio n o f the volume , pressur e drop , an d temperatur e o f the contaminate d ai r an d the volume an

d pressur e o f the scrubbing mediu m(water) . Deviatio n fro m establishe d norm s can b e checke d b yreferenc e t o record s o f previou s plan t inspections . Th e inspecto r shoul d examin e th e seal s a t manhole s an d duc t collar s fo r tigh t fi t an d shoul d chec k th e devic e fo r remova l o f solid s an d spen t scrubbing liquid s t o ensur e tha t

6- 6

### P.7 8 

# V , /

i t i s no t blocke d partiall yopen . Wit ha "variabl e venturi "

typ e scrubber , th e inspecto r mus t b e provide d wit ha recor d o f th e "normal " setting . Wate r i s introduce d internall y througha nozzl e o r sprays , which , i f blocke d o r inoperativ e coul d affec t a zon e o f th e ventur i adversely . Th e moistur e separator s and/o r demister s o f a scrubbe r installatio n maybecom e blocked , o r partiall yso , particu
larl yi f theyinclud e a screen . Particula r attentio n shoul d b e give n t o "ball-bed" , "packe d tower, " an d "packe d bed " type s o f scrubbers , whic hincorporat e a supplementa l interna l featur e tha t maybecom e blocke d o r caus e resistanc e t o th e flo wo f ga s o r liquid . Screen s Fugitiv e dus t emission s occu r a t th e screen s whe n fin e coa l i s involved . Th e coa l preparatio n plant s generall yus e thre e type s o f screens : grizzly , shaker , an d vibrating . Grizzl yscreen s ar e use d o n ROM coa l precedin g a crushe r o r loading a bel t conveyor . Theyusuall yar e serve d b yspray s bu t ar e sometime s enclosed . Th e doors , plates , an d seal s o f th e enclosur e ar e highl ysubjec t t o damag e b y piece s o f meta l o r rock . We t incoming materia l ma ycaus e pluggin g o f th e branc hai r duc t fromth e enclosur e t o th e dus t collector , whic hshoul d b e size d t o carrydust-lade n air , a t th e minimu

m pressur e available , a t a velocit yo f no t les s than 450 0 fpm .

6- 7

### P.7 9

Shake r screen s ar e use d infrequently , rarel yproviding a separatio n les s tha n 2 inche s (usuall ymuc hlarger) . A hoode d enclosur e mayb e foun d alongsid e th e screen . Prin
cipa l malfunction s involv e plugging , short-circuiting , o r imprope r sizing o f th e conveyin g ducts , damag e t o th e hood , o r imprope r placemen t o f th e hood . Avibratin g scree n i s th e mos t commo n separating device . Man yscreen s ar e floode d wit hwate r an d constitut e n o dus t source . Th e "dry " screen s usuall ymak e a separatio n a t 1/4
- 3/8-1/ 2 inc han

d creat e fugitiv e dust . Malfunction s involv e loos e seals , damage d enclosures , ope n acces s doors , an d blocke d o r short-circuite d ai r ducts . Crusher s Crushers , a n importan t sourc e o f fugitiv e dust , ar e protecte d b

yspray s o r dus t collectors . Asudde n appearanc e o f fugitiv e dus t mayb e cause d b yblockag e o r short-cir
cuitin g o f ai r ducts , broke n enclosure s o r seals , o r ope n acces s doors . I f operatio n o f th e crushe r i s changed , a n upse t mayoccur . Ahammermil l wil l respon d t o highe r speed s wit hfine r produc t and/o r greate r capacity , creatin g a ne w situatio n fo r dus t control . Introductio n o f a coa l o f sof t consistenc yals o ca n introduc e ne wproblems . Breaker s ar e subjec t t o th e same type s o f malfunction s describe d fo r crushers , cause d b ybroken , loose , o r mis
6- 8

### P.8 0 

## V t

place d enclosures , blocke d o r short-circuite d ai r ducts ,

ope n acces s doors , and overloading . Similarly , chang e o f perforate d plate s t o reduc e th e sizing o r introductio n o f coa l fromdifferen t seam s ca n caus e fugitiv e dus t emissions . Conveyo r Transfe r Point s Conveyo r transfe r point s ar e source s o f fugitiv e dus t whe n drycoa l containin g the 3/ 8 x 0 inc hincremen t i s processed . I f th e materia l i s large r than 3/ 8 inc ho r surfac e moistur e conten t exceed s abou t 9 percent , dus t emission s d o no t occur . Th e enclosur e usuall yha s a n acces s door , whic hmayb e remove d o r lef t open , thu s short-cir
cuiting th e "pickup " air . Rubbe r seal s o r curtain s als o may b e remove d o r damaged . Airflo wma yb e insufficien t t o gathe r th e dust . Th e duc t carrying th e dust-lade n ai r away mayb e blocked , broken , o r poorl ysized . Adampe r mayb e i n th e wron g position , o r th e chut e leading fro mthe conveyo r pulleymayb e blocked , permittin g spillage . Th e duc t shoul d carryth e volum e o f ai r a t a velocit yo f 450 0 fpm . Prope r conveyin g pressur e mayb e unavailabl e becaus e o f malfunctio n o r overloading o f the collecting devic e a t th e duc t terminal . Speedin g o r overloadin g o f a conveyo r may caus e an emissio n upse t a t the terminal . Referenc e t o earlie r inspectio n report s wil l disclos e an ydeviatio n from th e norma l flo wo f coa l a t a give n point . Mos t o f th e

6- 9P.8 1

malfunction s describe d abov e ar e readil yhandle d bymain
tenanc e and replacemen t o f damage d components . Storag e Facilitie s Storag e bin s o r silo s includ e severa l possibl e fugitiv e dus t sources . Th e feede r underneat ha bi n ma yb e enclose d i n a structur e simila r t o tha t a t a bel t conveyo r transfe r poin t jus t described , an d th e sam e malfunction s ma yoccur . Mos t storag e bin s an d silo s ar e covere d and ar e loade d byth e conveyor . Th e conveyo r discharg e ha s bee n discussed , bu t a supplementa l bi n exhaus t shoul d b e presen t t o equaliz e pressur e insid e agains t th e volum e o f incomin g coal . Thi s por t i s sometime s equippe d wit ha bi n ven t filter , whic hca n becom e plugge d becaus e o f infrequen t filte r change s o r exposur e t o water . Th e bi n ma yals o hav e duct s leadin g fro m thes e vent s t o a centra l dus t collector . Th e bi n shoul d b e exhauste d a t a n ai r volum e rat e equa l t o twic e th e volum e o f incomin g coal . Emission s ma yoccu r i f thi s amoun t o f ai r i s no t provide d o r i f th e line s fro mth e bi n ar e inadequate , a s discusse d wit hrespec t t o conveyors . Athir d possibl e emissio n sourc e i s presen t o n a fe w silos , usuall ystorin g ROM , whic hhav e larg e opening s throug hth e wall s nea r th e to p and aroun d th e circumferenc e a t space d intervals . Thes e opening s ma yhav e doors , whic h ar e normall yclose d t o contai n th e coa l withi n th e silo .

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### P.8 2

Coa l i s release d upo n operato r demand o r whe n the silo s become nearl yfull , flowing throughth e hole s t o ope n storag e around the silo . Thi s operatio n can produc e sub
stantia l fugitiv e dus t emissions . Loading an

d Unloadin g Station s Th e point s a t whic houtgoin g coa l i s loade d an d in
comin g coa l i s receive d constitut e significan t source s o f fugitiv e dus t emission s becaus e o f th e larg e volume s o f coa l tha t ar e handled , ofte n withou t adequat e controls . Th e chutes , hoods , bins , an d miscellaneou s ful l o r partia l enclosure s involve d i n unloadin g an d loading operation s ar e subjec t t o th e same malfunction s describe d earlie r wit h respec t t o simila r equipmen t elsewher e i n the plant : passage s ar e blocke d o r plugged , acces s door s ar e remove d o r lef t ajar , seal s ar e broke n o r faulty , meta l component s ar e dented , corroded , o r otherwis e deteriorated . Essentiall y simpl e structure s o r device s mayb e inoperabl e becaus e o f damag e tha t i s undetecte d o r ignored . Th e tas k o f the inspecto r i s t o not e an d recor d al l actua l o r possibl e point s o f dus t emissio n requirin g th e attentio n o f plan t operators . Certai n point s o f th e coa l transfe r operations , however , ar e worth

yo f specia l note . Unloadin g fro

mrailroad car s mayinvolv e th e us e o f retractabl e chutes , operate d pneumatically , whic hofte n los e

6-1 1

### P.8 3

t i I ! I t 

### precisio n becaus e o f wea r o r errati c powe r supply . Con ventiona l loadin g o f railroa d car s i s sometime s protecte d b y oi l spraying , th e effectivenes s o f whic hmayb e deteriorate d b ybroke n o r plugge d spray s an d lines , damage d pump s o r tanks , errati c pressur e contro l valves , an d insufficien t oi l supply . Barg e loading i s b ychute , retractabl e t o a degre e bu t stil l permittin g fre e fal l o f th e coa l int o th e barges . I n stockpil e loading b yconveyor , coa l i s discharge d froma conveyo r highi n th e ai r an d fall s eithe r throughretractabl e chute s o r loading stacks . Loading stack s ar e hollow , stationarycolumns , eithe r o f stee l o r concrete , reaching fromth e ground t o th e bel t conveyo r discharge . Theyhav e staggere d partia l opening s a t differen t elevations , extending th e entir e length , t o offe r some protectio n from th e wind an d t o permi t accumulatio n o f th e stockpil e around th e exterior . I f th e closure s ar e blocke d i n a n ope n position , advers e ai r current s mayb e generated . I n al l o f th e loading operations , windbreak s ar e essentia l fo r contro l o f ai r currents . Thes e shoul d b e wel l place d wit hrespec t t o prevailing winds , an d mus t b e wel l maintaine d fo r maximu meffectiveness . Th e dus t emissio n problem s involve d a t station s fo r unloadin g o f th e ROM coa l naturall yar e simila r t o thos e a t loading points .

6-1 2

### P.8 4



# - 1

Truc k dum p bin s sometime s ar e partiall yenclosed . Sheetin g mayb e absen t fromthes e enclosures , eithe r delib
eratel yo r b

yaccident . Man

ysuc hbin s hav e no dus t contro l system . An

yhoode d dus t contro l mus t allo wfo r veryhigh airflo wbecaus e o f the highrat e a t whic hth e ai r i n th e bi r i s exhausted . Station s fo r unloadin g o f railroa d car s ar e normall y housed , an

d th e fugitiv e dus t i s controlle d b ysprays . Thos e wit hdust-collectin g hood s ar e subjec t t o th e mal
function s describe d earlier . 6. 5 MALFUNCTIONO F CONTRO L DEVICE S Malfunction s o f contro l device s principall yinvolv e scrubbers , cyclones , sprays , baghouses , an d dus t collectio n systems . Scrubber s hav e bee n discusse d i n connectio n wit h therma l dryers . Acyclon e shoul d b e installe d t o operat e o n prede
termine d volume s o f particulate-bearin g ai r a t give n tem peratur e limits , wit ha minimu mstipulate d recoveryo f particle s i n the variou s siz e ranges . Recoveryi s deter
mine d b ythe shap e o f th e cyclon e an d th e volum e flo w throughit . Thi s i s tru e o f al l cyclones , whethe r singl e o r i n clusters , larg e o r small , ho t o r cold . Detectin g th e caus e o f a malfunctio n wil l involv e isolating th e circumstanc e tha t ha s change d sinc e norma l operatio n wa s recorded .

6-1 3

### P.8 5

Ai r volum e can b e measure d a t th e outle t o f the cy clone . I t mayb e lowi f th e fan i s worn , belt s ar e loos e o r broken , o r intak e are a i s n o longe r sufficien t t o pas s adequat e ai r a t th e pressur e available . Blockag e anywher e i n the systemi s equall ydamaging . Temperatur e ca n b e measure d a t th e cyclon e inlet . I f i t deviate s fromth e desig n limits , the volum e o f ai r a t a give n pressur e wil l b e incorrect . Temperatur e variation s o f thes e proportion s woul d probabl yreflec t the introductio n o f heate d air . Determining pressur e dro p "acros s th e cyclone " require s pressur e reading s befor e an d afte r th e device . Commo n problem s ar e a wor n vacuu mpump , loos e belts , an d a n opening i n the duc t following the cyclone . I f the pressur e i s constan t a t the fan , the pressur e ha s increase d downstream fro mthe cyclon e o r an acciden t ha s occurre d withi n the cyclone . Th e shap e o f the cyclon e ca n b e change d b ylarg e dents , fallou t o f th e refractoryliner , mechanica l failur e o f the feede r discharging solid s a t the bottom , an d b yblockag e du e t o accumulatio n o f fir e clayo r we t fin e coa l o n the in
terio r walls . I n a wet-wal l cyclone , the flowo f liqui d down the interio r wall s ma yb e inadequat e t o reac hth e bottom , causing buildu p o n the interior . I n cyclon e clusters , partia l blockag e o f an yo f th e severa l smal l unit s ca n

6-1 4

### P.8 6

reduc e the flo wo f air . A s wit hman yo f the processing components , a chang e i n analysi s o f incoming coa l can caus e difficulty . Spra ysystem s i n a coa l preparatio n plan t can rang e fromlow-pressur e "fis htails " o r hollow-nozzl e type s t o high-pressur e (30 0 psi ) impingemen t types . Awetting agen t i s occasionall yuse d i n the spra ywater . Appearanc e o f excessiv e particulat e probabl ymayb e trace d t o on e o f the following causes :

0 

### Introductio n o f mor e tha n norma l amount s o f dust . ° Misalignment , damage , o r plugging o f spra yhead s o r header . ° Damag e o f a contro l valve . ° Plugging o f a lin e filte r o r incoming line . ° Wea r o r damag e o f pum p o r drive . ° Lac k o f water . 0 

### Damag e o f senso r devic e o r on-of f switch . ° Accumulation s o f ic e i n line s o r spra yheads . Th e criteri a fo r successfu l operatio n o f fabri c filter s ar e pressur e dro p acros s th e baghouse , temperatur e o f the incoming air , an

d th e volum e o f ai r pe r surfac e are a o f filte r fabric . Othe r possibl e cause s o f fugitiv e dus t emission s includ e the usua l factor s involving wear , damage , looseness , plugging , o r othe r impediment s t o effectiv e operatio n o f fans , blowers , ducting , hoppers , an d simila r

6-1 5

### P.8 7

components . I n addition , the inspecto r ma ychec k fo r th e following : ° Ne wbag s pas s fin e particulat e unti l theybecom e permeate d an

d coated . I f ne wfabri c i s use d i t ma yno t b e compatibl e wit hth e ai r velocity , temperature , o r pH coun t o f th e stream . 0 

### Interio r diaphragm s mayb e puncture d o r loose . 0 

### Cleanin g cycle s mayremov e to o man ybag s fromthe circuit , leaving a n inadequat e numbe r i n operation . Thi s i s mos t likel yt o occu r jus t befor e planne d maintenance , whe n a numbe r o f bag s ar e tie d off . ° Th e collecting hoppe r belo wthe bag s mayb e fille d wit hdust . Foreig n material s (bags , hose , tools ) sometime s ente r th e hoppe r an d caus e blockage . 0 

### Ba g cleanin g ma yb e neglecte d i n manua l operation , o r th e rapping o r shaking mechanism s maysuffe r mechanica l failure ; revers e ai r je t (pneumatic ) system s o r timing device s mayfai l o r becom e plugged . ° Bypassin g device s maybecome damaged , partiall yo r completel yblocked , o r ou t o f cycle . System s fo r collectio n o f dus t fromvariou s source s throughou t th e plan t ar e mad e u p o f hood s an

d enclosure s a t emissio n points , wit hduct s leading t o juncture s an d finall y t o a majo r duc t t o the collecting device , usuall ya bag
house . Eac ho f the branc hline s o r duct s mus t b e properl y size d t o maintai n adequat e flow . Ai r intake s o r cleanout s locate d a t critica l point s ar e equippe d wit hdamper s (valves) , whic hca n caus e malfunction . Connectio n o f branc hline s t o large r one s mus t no t b e sharp (45° , preferabl y30° ) and shoul d ente r fromth e to p o r sides , neve r opposing . Any

6-1 6

### P.8 8 

# h /

ben

d i n th e ductin g shoul d hav e an insid e radiu s o f 2 time s the pip e diameter . Introductio n o f wate r int o the duc t collectio n systemi s anothe r sourc e o f potentia l trouble .

6-1 7

### P.8 9

7. 0 EMISSIONPERFORMANC E TEST S Th e emissio n performanc e test s ar e intende d t o ser _ 

### ' e a s a basi s fo r determinin g complianc e statu s o f th e plan t during late r inspections . Thes e initia l performanc e tests , therefore , mus t b e conducte d unde r condition s tha t ar e representativ e o f plan t operation . Tw o factor s ar e o f paramoun t importance : th e coa l bein g cleane d an d th e equipmen t loading s during th e test . Analysi s o f th e coa l processe d i n th e tes t shoul d b e typica l wit hrespec t t o percentag e o f fine s an d moistur e content . Similarly , equipmen t loadings , whic husuall ywil l diffe r from the rate d o r design capacities , shoul d represen t the maximu m con tinuou s loading in plan t operation . A s discusse d i n the balanc e o f thi s section , th e inspecto r wil l wor k wit hplan t official s an

d th e emission s testing contracto r i n selectio n o f proces s paramater s fo r the emission s test . 7. 1 PRETES T PROCEDURE S Befor e detail s o f the tes t procedur e ar e established , the EP Ainspecto r shoul d discus s the tes t objective s wit h th e person s involved . I n providin g background informatio n fo r plan t personnel , he wil l enhanc e thei r understandin g o f tes t

7- 1

### P.9 0

procedure s an

d thu s establis ha framewor k i n whic hcoop erativ e effor t i s likely . Thes e pretes t discussion s wil l focu s o n thre e principa l areas : th e NSPS , th e operatin g parameters , an

d th e tes t schedule . NSP S Briefing Th e inspecto r shoul d b e prepare d t o explai n the back
ground o f the Ne wSourc e Performanc e Standard s an d thei r relationshi p t o the overal l EPAgoals . H e shoul d giv e detail s o f th e procedure s use d b yEPAi n setting the stan dard s an

d explai n th e unit s i n whic hemission s ar e reported , a s require d b

yregulations . H e wil l poin t ou t tha t the NSP S specificall yrequir e monitorin g o f therma l drye r temperature , wate r suppl ypressur e t o the ventur i scrubber , an d pressur e los s i n the ventur i constriction . Althoughdetail s o f plan t operatio n ar e highl yvariable , th e inspecto r wil l fin d tha t detaile d knowledg e o f coa l cleaning processe s an d o f EPA activitie s wil l enabl e hi mt o answe r question s effectively . Operatin g Parameter s Th e effect s o f al l th e majo r proces s variable s wil l determin e selectio n o f proces s parameter s durin g th e emis
sio n performanc e tests . Th e selecte d value s shoul d repre sen t th e highe r extrem e o f emissio n level s encountere d i n plan t operations . A s mentione d earlier , the majo r proces s variable s affectin g emission s ar e coa l analysi s (fine s an d moisture ) an

d fee d rate .

7- 2/ 

## \x i)j A P.9 1

Th e percentag e o f fine s i n th e fee d enterin g a therma l drye r o r ai r tabl e wil l directl yand proportionall yaffec t th e potentia l emission s throug hth e equipment . Greate r percentage s o f fin e coa l i n th e fee d ma yresul t i n large r amount s o f particulat e matte r escapin g throug hth e contro l devic e t o th e atmosphere . Fo r contro l o f emission s t o th e leve l specifie d b yth e regulations , a highe r pressur e dro p woul d b e require d acros s th e scrubber . Therefore , th e percentag e o f fine s i n th e fee d durin g a performanc e tes t shoul d represen t th e highe r extreme s encountere d i n con tinuou s plan t operation . Moistur e conten t o f fee d coa l ha s a simila r direc t effect . Notic e also , however , tha t highe r moistur e conten t o f th e fee d wil l resul t i n reductio n o f ai r tabl e emission s an d fugitiv e dus t emissions . Ahighe r moistur e conten t o f fee d enterin g th e therma l drye r ma yresul t i n flu e gase s wit hhighe r moisture , causin g potentia l difficult yi n assessin g complianc e wit hopacit ystandards . Th e fee d loa d (tonnage ) durin g th e performanc e tes t shoul d b e representativ e o f th e maximu n continuou s rat e a t whic hth e plan t i s operate d i n overloa d conditions . Thi s wil l ensur e representativ e hig hloadin g o f th e proces s equipmen t durin g th e test .



### 7- 3

### P.9 2

'C i Tes t Schedul e Th e emissio n performanc e tes t schedul e wil l b e deter
mine d jointl yb

yth e inspector , th e tes t contractor , an d plan t personnel . Plan t personne l shoul d provid e informatio n regarding th e schedul e an d analysi s o f coa l receipts , schedule d maintenance , operating schedule s an d simila r operatin g factors . Th e inspecto r wil l discus s full ywit h plan t personne l and th e tes t contracto r th e method s an d procedure s o f testing . Siz e o f tes t cre wwil l depend o n the numbe r o f sampling point s an d tota l tes t duration . A n experience d emissio n testing contracto r wil l b e abl e t o mak e tha t judgment , wit hconcurrenc e o f th e inspecto r an d plan t officials . Loca l weathe r condition s an d forecast s shoul d b e considere d a s th e testing time approaches . Significan t rainfal l o r snowfal l coul d limi t th e effectivenes s an d accurac yo f emission s tests . I t i s o f utmos t importanc e tha t th e inspecto r tak e prope r safet ymeasure s t o preven t mishap s durin g the plan t inspections . H e shoul d alway s us e persona l protectiv e equip
men t suc ha s har d hat , safet yglasse s o r goggles , ea r plugs , safet ybelts , an

d safet yshoe s during th e plan t visit . Wher e th e plan t prescribe s standar d safet yprocedure s fo r protectio n o f staf f an d visiting personnel , h e shoul d adher e t o thes e strictl ydurin g th e inspections . 7- 4

### P.9 3 KfS I:



### Tabl e 7. 1 outline s majo r plannin g responsibilitie s o f

th e thre e group s involve d i n emissio n performanc e tests . 7. 2 TES T MONITORING I t i s importan t t o remembe r tha t th e initia l emission s test s determin e th e reliabilit yo f late r emissio n complianc e inspection s an

d tests . Al l person s involve d i n th e emission s test s shoul d see k t o ensur e tha t the test s ar e conducte d fairl yan

d th e tes t result s ar e valid . Th e inspecto r play s a majo r rol e i n monitorin g the tes t procedure s an

d plan t operatin g parameter s durin g the tes t period . H e mus t ensur e tha t the test s ar e carrie d ou t accordin g t o standar d procedures . Th e following ar e keyfactor s t o b e monitore d con tinuousl ydurin g th e tests : ° Plan t fee d rate . ° Percentag e o f fine s an d moistur e conten t o f th e feed . ° Ai r tabl e fee d rat e an d baghous e pressure . ° Therma l drye r fee d rat e an d exi t ga s temperature . ° Duration s an

d interval s o f emission s tests . Tabl e 7- 2 present s a detaile d inspectio n checklis t t o ai d the inspecto r i n performin g hi s dutie s i n a thoroughan d objectiv e manner . A t leas t thre e set s o f proces s observation s air e rec ommended . Th e numbe r o f stac k tes t observation s durin g

7- 5

### Tabl e 7-1 . EMISSIONPERFORMANC E TES T RESPONSIBILITIE S P.9 4

Group/Perso n EP AInspecto r

Plan t Personne l

Tes t Contracto r o

o

o
o

o

o

o

o o 0

o

o

o

o

o 

### Responsibilitie s Arrang e pretes t meeting ; explai n tes t goal s an

d procedures . Revie wan

d approv e tes t schedul e prepare d b

ytes t contractor . Chec k locatio n o f tes t points . Selec t tes t fee d analysi s an d fee d rat e i n consultatio n wit hplan t personne l an

d reques t tha t majo r parameter s b e recorded . Observ e "an

d follo wnorma l safet ypro cedure s an

d thos e specifie d a t th e pl a Provid e informatio n fo r inspecto r regarding type s o f coal s cleane d an d maximu

mfee d rates . Provid e wor k are a fo r tes t contrac tor . Identif yemissio n points . Identif yan

d prepar e ports . Provid e detail s o f stac k site s an d contro l equipment . Provid e detail s o f plan t instru
mentation . Provid e equipmen t maintenanc e schedule ; selec t tes t date s i n consultatio n wit hinspecto r an d tes t contractor . Presen t tes t schedul e t o equipmen t operator s an

d supervisors . Familiariz e tes t cre wwit h tes t sites , methods , an d NSP S requirements . Prepar e tes t schedule ; obtai n approva l fro

minspecto r an

d plan t personnel . 7- 6r" i



# V P.9 5

Tabl e 7-2 . CHECKLIS T FOR PERFORMANC E TES T GENERAL INFORMATIO

N Plan t Name : Min e Name : Plan t Address: . Contac t a t Plant : Dat e o f Inspection: . Inspecte d by :

Plan t Rate d Fee d Capacity , ton/hr: . Plan t Fee d Rate , ton/hr : Yea r o f Plan t Commissioning / Majo r Modification : Facilit yData : Cleanin g Technique s Numbe r o f Stacks : We t Dry Other . (continued )

7- 7

### P.9 6

Tabl e 7- 2 (continued ) COAL DAT

A
COA L SEAM :

Siz e Surfac e moisture , % 1/4x0 , % Ash , % Stri p mining , % Continuou s mining , % Conventiona l mining , % Rawcoa l a s receive d 1 2 3

. 

### Refus e coa l 1 2 3

(continued )

7- 8Tabl e 7- 2 (continued) . EQUIPMEN T CHECKLIS T P.9 7

WEIGHIN G DEVICE :

• Availabl e Q No t Availabl e 

### Type : Scal e desig n capacity: . Siz e o f coa l weighed :
Las t dat e o f calibration : 

### • RO M

• Other Prescribe d calibratio n frequency: . 

### • l/ 4 x 0

Plan t hourl yfeed 1s t hou r 2n

d hour rat e during'inspection , ton/hr 3r d hour 4t hhour 5thhour 6t hhour

Averag e hourl yfee d rate , ton/hr : Maximumhourl yfee d rate , ton/hr :
PRIMAR Y CRUSHER/CRUSHE R ENCLOSUR E Fee d rate : Fee d capacit y Loa d current: . ton/h r ton/h r ampere s Fugitiv e dus t control : [~]Goo d • Poo r Type:Qspra y• Cyclon e •Fab . Filte r Opacit yo f Emission: 3 %

Us e EP AMetho d 9 fo r al l opacit yreading s (continued ) 

### 7- 9

### P.9 8 

# rf

I - i

• i I

i' i I

\\ I 

### Tabl e 7- 2 (continued) .

SECONDARY CRUSHE R Fee d rate : Fee d capacity: . Loa d current: _ ton/hr ton/hr Fugitiv e dus t control : Type : | | Spray Opacit yo f Emission: . ampere s I | Goo d | I Poo r I I Cyclon e I I Fab . Filte r

AI R TABL E

(continued ) Tabl e No . Baghous e No . Baghous e AP , in . Loa d current , ampere s Cyclon e No . Cyclon e AP , in . Stac k ga s opacity , % Ga s flo wrate , acf m Particulat e loading , gr/dsc f Opacity , % Fee d rate , t/h

r 1 2 3 4

•t

### 7-1 0P.9 9 

### A Tabl e 7- 2 (continued) .

SCREENS/ENCLOSURE S

Locatio n Fee d rate , ton/h r Moistur e content , % Produc t size s Fugitiv e dus t controls : Type : Spra y

Cyclon e Fab . Filte r Opacit yo f emission , % Scree n No . 

### 1 2 3 4

THERMA L DRYE R Typ e Drye r fee d rate: . Drye r fee d size : Fee d moistur e content : Produc t moistur e content : Fa n loa d current : Fa n suctio n AP : Dryin g chambe r A P .Btu Ratin g ton/h r .ton/hr

. % % ampere s in , vac . in , vac . Flu e ga s temperatur e a t drye r exit : normal_ _ (fo r las t 1 2 hrs . o f continuou s maximu m norma l operation ) minimu m Las t dat e o f temperatur e recorde r calibration : = Cyclon e outle t temperature: . Cyclon e AP : in . (continued ) _°F _°F

7-1 1 

### vP.10 0 

# i l Tabl e 7- 2 (continued) . FLU EGA S SCRUBBE

R Type : 0 Wate r suppl ypressur e (fo r las t 1 2 hrs . o f continuou s norma l operation )
° Pressur e los s a t scrubbe r (fo r las t 1 2 hrs . o f con tinuou s norma l operation ) Las t dat e o f recorde r calibration : Prescribe d frequenc yo f calibration : Norma1 _ Maximum . Minimum . Normal _ Maximu m Minimu m

Opacit yo f flu e ga s a t stac k exit , % Particulat e concentratio n a t exit , gr/dscf: . .in , .in , in , .in . .in , .in .

CONVEYOR/TRANSFE R POINT S Dra wa roug hsketc ho f facilit ylayou t indicatin g an d num berin g th e conveyors , usin g th e grap hpape r o n followin g pag e Us e sam e number s t o identif yth e conveyor s i n th e followin q table : y

Locatio n Receivin g uni t Discharg e conveyo r width , Discharg e conveyo r speed . Rate d capacity , ton/h r Loa d current , ampere s Typ e o f dus t control : spra y cyclon e fab . filte r Wate r press , in . Wate r flow , gp m Opacit yo f emission , % in . ft/min . Conveyo r No .

1 2 3 4

(continued ) 7-1 2 _jP. 1 Tabl e 7- 2 (continued )

FACILIT YLAYOU

T (continu e 7-1 3

### Tabl e 7- 2 (continued) . P3.

LOADIN G STATIO

N Type : I I Truc k Railroa d 1 I Barg e

Quni t Trai n L_

J Othe r Fee d capacity : Actua l fee d rate : Exten t o f dus t control : Fa n load Current : I ] Goo d 1 I Poo r ampere s ton/hr ton/hr

Typ e o f dus t control : I Ispray : Wate r suppl ypressur e in. , flowgp m I I Cyclone : Pressur e dro p in. , flowcf m L J Fabri c filter : Pressur e drop . j.n . , flowcf m

Conditio n o f collecto r bag s Emissio n opacit y%
UNLOADIN

G STATION Type : I I Truc k Barg e | | Railroa d Fee d capacity : ton/hr Actua l fee d rat e : ton/hr Typ e o f Contro l device : 1 ] Spray : Pressur e dro p in . , flowgp m in . , flowcf m Fabri c filter : Pressur e dro p in. , flowcf m I I Cyclone : Pressur e dro p

Emissio n opacit y (continued ) Conditio n o f collecto r bag s %



### 7-1 4 U t

### P. 3

7- 2 (continued) . COA L STORAG E Type : 

# • sil

o • Fabricate d Bi n Location : Siz e o f coa l stored : _ Typ e o f coa l stored:_ _ Dus t contro l device : I I Spra y Wate r suppl ypressur e I I Cyclon e Pressur e dro p [ZI Fabri c filte r Pressur e dro p Fa n load curren t Rawcoa l Washe d coa l

.in' . , flo w _gp

m in. , flow . in. , flow amps . Conditio n o f collecto r bag s Storag e desig n fee d rat e ton/hr Actua l fee d rat e ton/hr cf m cf m

(continued )

7-1 5

### Tabl e 7- 2 (continued) . FIEL D OBSERVATIO N CHECKLIS T 

### P. 4

GENERAL/ADMINISTRATIV E PLAN T NAM

E PLAN T ADDRES S SOURC E T O B E TESTE D PLAN T CONTAC T J)ATE .

PHON E OBSERVER S AFFILIATION

REVIEWE DTES T PROTOCOL ? COMMENTS , REVIEWE DPRETES T MEETINGNOTES? . COMMENT S

i ; • REVIEWE DCORRESPONDENCE ? COMMENT S

TES T TEA M COMPANYNAME SUPERVISOR' S NAME OTHE RMEMBER S ADDRES S TITL E _ PHON E

i:i| :

r i ii 

### (continued ) 7-1 6 J

### P. 5

Tabl e 7- 2 (continued) . GENERAL/SAMPLIN GSIT E STACK/DUC T CROSS-SECTIO NDIMENSION S EQUIVALENT DIAMETER . MATERIA L O F CONSTRUCTIO NCORRODED ? LEAKS ? INTERNAL APPEARANCE : CORRODED ? CAKE D PARTICULATE ? THICKNES S INSULATION ? THICKNES S LINING ? THICKNES S NIPPLE ? I.D . LENGT H FLUS H WIT H INSID E WALL ? STRAIGH T RU

NBEFOR E PORT S DIAMETER S STRAIGH T RU

NAFTE RPORT S DIAMETER S PHOTO S TAKEN ? O F WHA T DRAWINGO F SAMPLINGLOCATION :

MINIMUMINFORMATIONONDRAWING : STACK/DUC T DIMENSIONS , LOCATIONAN D DESCRIPTIO NO F MAJO RDISTURBANCE S AN D AL L MINO RDISTURBANCES , TRANS MISSOMETERS , AN D CROSS-SECTIONA L VIE WSHOWINGDIMENSION S AN D POR T LOCATIONS . (continued )

7-1 7X l 1:1



### i f !

i l l • 

### P. 6
Tabl e 7- 2 (continued ) GENERAL/SAMPLIN GSYSTE M
SAMPLINGMETHO D (e.g. , EP A5 ) SAMPLINGTRAI NSCHEMATI C DRAWING :

MODIFICATION S T O STANDAR D METHO D PUM P TYPE : FIBERVAN E WIT H IN-LIN E OILE RCARBO NVAN E DIAPHRAG M PROB E LINE RMATERIA L HEATED ? ENTIR E LENGTH ? TYP E "S " PITO T TUBE ? OTHE R PITO T TUB E CONNECTE D TO : INCLINE D MANOMETE RO RMAGNEHELI C GAUG E RANG E APPROX . SCAL E LENGT H DIVISION S METE RBO XBRAND SAMPL E BO XBRAND RECEN T CALIBRATIO NO F ORIFIC E METER-DR YMETER ? PITO T TUBES ? NOZZLES ? THERMOMETER S O RTHERMOCOUPLES ? MAGNEHELI C GAUGES ? NUMBE RO F SAMPLIN GPOINTS/TRAVERS E FRO MFED . REG . NUMBE RT O B E USE D LENGT H O F SAMPLIN GTIME/POIN T DESIRED ^ TIM E T O B E USE D (continued )

7-1 8

### P. 7 Tabl e 7- 2 (continued) . SAMPLIN G(US E ON E SHEE T FO REAC H RU NI F NECESSARY ) RU N# _ PROBE-SAMPL E BO XMOVEMEN T TECHNIQUE : I S NOZZL E SEALE D WHE NPROB E I S INSTAC K WIT H PUM P TURNE D OFF? . I S CAR E TAKE NT O AVOI D SCRAPIN GNIPPL E ONSTAC K WALL ? I S A NEFFECTIV E SEAL MAD E AROUN D PROB E A T POR T OPENING ? I S PROB E SEA L MAD E WITHOU T DISTURBINGFLO WINSID E STACK? . I S PROB E MOVE D T O EAC H POIN T A T TH E PROPE RTIME ? I S PROB E MARKIN GSYSTE MADEQUAT E T O PROPERL YLOCAT E EAC H POINT ? AR E NOZZL E AN D PITO T TUB E KEP T PARALLE L TO . STAC K WAL L A T EAC H POINT? . I F PROB E I S DISCONNECTE D FRO MFILTE RHOLDE RWIT H PROB E I NTH E STAC K O NANEGATIV E PRESSUR E SOURCE , HO W I S PARTICULAT E MATTE RI NTH E PROB E PREVENTE D FRO MBEIN GSUCKE D BAC K INT O TH E STACK ? I F FILTER S AR E CHANGE D DURINGARUN , WA S ANYPARTICULAT E LOST ? METERBO XOPERATION : AR E DATARECORDE D INAPERMANEN T MANNER ? AR E DATASHEET S COMPLETE ? AVERAG E TIM E T O REAC H ISOKINETI C RAT E A T EAC H POIN T I S NOMOGRAP H SETTIN GCHANGE D WHE NSTAC K TEMPERATUR E CHANGE S SIGNIFICANTLY ? AR E VELOCIT YPRESSURE S (Ap ) READ AN D RECORDE D ACCURATELY ? I S LEAK TES T PERFORME D A T COMPLETIO NO F RUN ? cf m @ I NHg . PROBE , FILTE RHOLDER , IMPINGER S SEALE D ADEQUATEL YAFTE RTEST ? , GENERA L COMMEN T ONSAMPLIN GTECHNIQUE S I F ORSA T ANALYSI S I S DONE , WA S IT : FRO MSTACK ? FRO MINTEGRATE D BAG ? WA S BAGSYSTE MLEAK TESTED ? WA S ORSA T LEAK TESTED ? CHECKE D AGAINS T AIR ? I F DATASHEET S CANNO T B E COPIED , RECORD : APPROXIMAT E STAC K TEMPERATUR E ° F NOZZL E DIA . IN . VOLUM E METERE D AC F LIS T AL L Ap.READING S
7—I Q 

### (continued ) ' 7• V i ' ; I

: l ' P. 8 t

Tabl e 7- 2 (continued) . 

### TRAI NASSEMBLY/FINA L PREPARATION S (US E ON E SHEE T PE RRU NI F NECESSARY ) RU N§. FILTE RHOLDE RCLEA

NBEFOR E TEST ? FILTE RHOLDE RASSEMBLE D CORRECTLY? . FILTE RMEDI ATYP E FILTE RCLEARL YIDENTIFIED ? FILTE RINTACT? . PROB E LINE RCLEANBEFOR E TEST ? NOZZL E CLEAN ? NOZZL E UNDAMAGED? _ IMPINGER S CLEA

NBEFOR E TEST ? IMPINGER S CHARGE D CORRECTLY ? BAL L JOINT S O R SCRE WJOINTS ? GREAS E USED ? KIND O F GREAS E PITO T TUB E TI P UNDAMAGED ? PITO T LINE S CHECKE D FO RLEAKS ? PLUGGING? . METE RBOXLEVELED ? PITO T MANOMETE RZEROED ? ORIFIC E MANOMETE RZEROED? . PROB E MARKING S CORRECT ? PROB E HO T ALON GENTIR E LENGTH ? FILTE RCOMPARTMEN T HOT ? TEMPERATUR E INFORMATIO NAVAILABLE? . IMPINGER S ICE D DOWN ? THERMOMETE RREADIN GPROPERLY? . BAROMETRI C PRESSUR E MEASURED ? I F NOT , WHA T I S SOURC E O F DATA? . AH @

### FRO MMOS T RECEN T CALIBRATIO NAH @

### FRO MCHEC K AGAINS T DRYGA S METE R NOMOGRAP H CHECK : I F AH @

### = 1.80 , T M = 100 ° F , %Hrfl = 10% , P s 

### /P m

### = 1.00 , C = (0.95 ) I F C^ = 0.95 , T S = 200 ° F , D N= 0.375 . A

p REFERENC E = (0.118 ) ALIGNAp = 1. 0 WIT H AH = 10 ; 0 A p = 0.01 , AH = (0.1 ) FORNOMOGRAP H SET-UP : ESTIMATE D METE RTEMPERATUR E ° F ESTIMATE D VALU E O F P s 

### /P m 

### . ESTIMATE D MOISTURE CONTEN T %HO WESTIMATED ? C FACTO RESTIMATE D STAC K TEMPERATUR E _° F DESIRE D NOZZL E DIAMETE R STAC K THERMOMETE RCHECKE D AGAINS T AMBIEN T TEMPERATURE ? LEAK TES T PERFORME D BEFOR E STAR T I F SAMPLING ? RAT E CF M @ IN . Hg . (continued )

7-2 0

### P. 9 

# n Tabl e 7- 2 (continued) .

SAMPL E RECOVER Y GENERA L ENVIRONMENT-CLEANU P ARE A WAS H BOTTLE S CLEAN ? BRUSHE S CLEAN ? BRUSHE S RUSTY? . JAR S CLEAN ? ACETON E GRAD E RESIDU E O NEVAP . SPEC . FILTE RHANDLE D OK ? _PROB E HANDLE D OK ? IMPINGER S HANDLE D OK? . AFTE RCLEANUP : FILTE RHOLDE RCLEAN ? PROB E LINE RCLEAN ? NOZZL E CLEAN ? IMPINGER S CLEAN ? BLANK S TAKEN ? DESCRIPTIO NO F COLLECTE D PARTICULAT E SILIC AGE L AL L PINK ? RU N1 RU

N2 RU

N3 JAR S ADEQUATEL YLABELED ? JAR S SEALE D TIGHTLY ? LIQUI D LEVE L MARKE D ONJARS ? JAR S LOCKE D UP ? GENERA L COMMENT S O

NENTIR E SAMPLINGPROJECT :
(continued !

7-2 1

### P.1 0

I ; •• >

, 1 

### Table.7- 2 (continued) . SAMPL E TRANSPOR T PARTICULAT E CHEC K LIS T Sample s ar e t o b e the direc t responsibilit yo f a senio r membe r o f the sourc e tes t tea m unti l the responsibilit yi s transferre d t o the laboratory j | supervisor . Al l liqui d sample s mus t b e airtight , the liqui d leve l marked , the n store d properl yuprigh t t o preven t spillag e o r breakage . Al l soli d sample s ar e t o b e seale d an d store d t o preven t th e los s o f sample s o r contaminatio n fro m th e ambien t sources . Al l sampl e container s mus t b e properl ymarke d on outsid e t o avoi d roughhandling durin g transpor t o f the sampl e t o th e laboratory . Al l sampl e container s locke d t o insur e th e sampl e integrit ydurin g transport . Th e sampl e lo g (chai n o f custody ) i s initiate d durin g sampl e recoveryt o insur e qualit yassuranc e fro mth e momen t o f collection . i i i 

# x 1 

### (continued ) vi ' , i

I'i x 

### fli 7-2 2

### P.1 1

Tabl e 7- 2 (continued) . ANALYTICAL PARTICULAT E CHEC K LIS T Analytica l balanc e shoul d b e calibrate d wit hClas s S weight s a t th e time o f use . Desiccato r contain s anhydrou s calciu msulfate . Filte r an

d an yloos e particle s fro mth e sampl e containe r desiccate d fro m2 4 t o 9 6 hour s t o a "constan t weight " mean s a differenc e o f n o mor e than 0. 5 m

g o r 1 percen t o f tota l weigh t les s tar e weight , whicheve r i s greater , betwee n consecutiv e weighings , wit hno les s than 6 hour s o f desicca
tio n time betwee n weighing s an d n o mor e than 2 minute s exposur e t o the laboratoryatmospher e (mus t b e les s than 50 % relativ e humidity ) durin g weighing . Recor d level*o f liqui d i n container s o n analytica l dat a shee t t o determin e i f leakag e occurre d durin g transport . Blank filter s desiccate d t o a constan t weight . Blank weigh t shoul d no t varyfromorigina l weigh t b ymor e than + 1. 0 mg . Liqui d i n sampl e container s remeasure d b yth e analys t eithe r volumetricall yt o + 1 m l o r gravi
metricall yt o + 0. 5 g . Acetone-rins e sample s evaporat e t o drynes s a t ambien t temperatur e an d pressur e i n a tare d 250-m l beaker . Preven t dus t o r object s fro menterin g th e beake r b

yplacing a watc hglas s ove r th e beake r durin g evaporation . Th e drie d sampl e wa s desiccate d t o a constan t weigh t an

d reporte d t o th e neares t 0. 1 mg . Th e aceton e blank wa s analyze d simultaneousl ywit h th e aceton e rins e using th e same procedures . (continued ) 7-2 3P.1 2 

### Tabl e 7- 2 (continued) . Silic age l wa s weighe dt o th e neares t 0. 5 g usin g abalanc e i nth e fiel do r laboratory . Sampl e beaker s covere dwit hparafil man dstore d alon g wit huse dfilter s unti l repor t i s accepte db y contro l agenc y o r

unti l suc htim e a s specifie db y th e agency .

WA S TH E TESTTEAM SUPERVISO R GIVE N TH E OPPORTUNIT YT O REA D OVE R THI S CHECKLIST ? DI D H E D

O SO? . OBSERVER' S NAME , .TITLE , AFFILIATION . SIGNATUR E 7-2 4

### P.1 3 

# n

emissio n performanc e test s wil l depend o n th e mutua l agree men t o f th e inspector , plan t operators , and tes t contractor ; fo r eac hse t o f stac k tes t data , correspondin g proces s dat a shoul d b e recorded . Aseparat e copyo f the checklis t fo r eac hse t o f observation s wil l facilitat e th e compariso n o f observations . Not e tha t NSP S regulation s specif yparticulat e con centration s onl yfo r therma l dryer s an d ai r tables ; al l othe r equipmen t i s governe d b yopacit yregulations . Th e value s observe d durin g th e tes t shoul d fal l withi n th e limit s prescribe d b yth e regulations . I f the yd o not , plan t official s shoul d b e notifie d s o tha t theymaytak e th e necessarycorrectiv e action . Th e inspecto r shoul d the n schedul e anothe r tes t i n accordanc e wit hagenc ypolicy .

7-2 5

### P. M

8. 0 PERIODI C COMPLIANC E INSPECTION S Periodi c inspection s following th e emission s perform
anc e test s wil l enabl e the inspecto r t o determin e the curren t complianc e statu s o f the plant . Th e inspectio n mainl yinvolve s compariso n o f curren t plan t operation s wit h thos e recorde d durin g th e emission s tests . Th e plan t instrumentatio n an

d record s constitut e th e majo r informatio n sourc e fo r the inspector . I n addition , he wil l us e th e emission s tes t checklis t fo r periodi c inspection , presente d a s Tabl e 8-1 . 8. 1 PERFORMING TH E PERIODI C INSPECTION Th e periodi c inspectio n generall yinvolve s the fol
lowing steps : ° Obtai n schedul e o f plan t operation s durin g the propose d inspectio n period . ° Stud

yal l availabl e plan t dat a including detail s o f th e performanc e tests , emissio n points , an d contro l equipment . ° Stud

yinstrumentatio n dat a gathere d i n performanc e tests . ° Not e unusua l characteristic s o f th e plant , an d comment s mad e b

ypreviou s inspectors . ° Informplan t official s o f th e propose d inspectio n an d ensur e tha t record s ar e curren t an d availabl e fo r inspection .



# r

### P.1 5

Tabl e 8-1 . CHECKLIS T FOR PERIODI C INSPECTIO N GENERAL INFORMATIO

N Plan t Name: . Min e Name : Plan t Address :
Contac t a t Plan t Dat e o f Inspection : Inspecte d by :

Plan t Rate d Fee d Capacity , ton/hr: . Plan t Fee d Rate , ton/hr : Yea r o f Plan t Commissioning / Majo r Modification : Facilit yData : Cleaning Technique s Numbe r o f Stacks : 

# H We t Dr y 

### • Other . (continued )

8- 2

### P.1 6

Tabl e 8- 1 (continued ) COAL DAT

A
COAL SEAM :

Siz e Surfac e moisture , % 1/4x0 , % Ash , % Stri p mining , % Continuou s mining , % Conventiona l mining , % Rawcoa l a s receive d 1 2 3 Refus e coa l 1 2 3

(continued )

8- 3P.1 7 Tabl e 8- 1 (continued) . EQUIPMEN T CHECKLIS T

WEIGHIN G DEVICE :

• Availabl e • No t Availabl e Type : Scal e desig n capacity : Siz e o f coa l weighed : • RO M

• Other . • l/ 4 x 0
Las t dat e o f calibration : Prescribe d calibratio n frequency: . Plan t hourl yfee d 1s t hou r 2nd hou r rat e durin g inspection , ton/h r 3r d hou r 4t hhou r 5t hhou r 6t hhou r

Averag e hourl yfee d rate , ton/hr : Maximumhourl yfee d rate , ton/hr :
PRIMAR Y CRUSHER/CRUSHE R ENCLOSURE : Fee d rate : Fee d capacity : Loa d current : ton/h r ton/h r ampere s Fugitiv e dus t control : •Goo d . • Poo r Type:Qspra y• Cyclon e •Fab . Filte r Opacit yo f Emission: 3 %
Us e EP AMetho d 9 fo r al l opacit yreadings . (continued ) 8- 4

### ft P.1 8

Tabl e 8- 1 (continued ) SECONDARY CRUSHE R Fee d rate : Fee d capacity: . Load current : ton/hr ton/hr ampere s 

## I I Goo dI | 

# • Poo r Fugitiv e dus t control : Type : I | Spra yCyclon e Fab . Filte r Opacit yo f Emission : %

AI R TABL E Tabl e No . Baghous e No . Baghous e AP , in . Load current , ampere s Cyclon e No . Cyclon e AP , in . Stac k ga s opacity , % Ga s flowrate , acf m Particulat e loading , gr/dsc f Opacity , % Fee d rate , t/h

r (continued '

8- 5P.1 9 Tabl e 8- 1 (continued) . SCREENS/ENCLOSURE S

Locatio n Fee d rate , ton/hr Moistur e content , % Produc t size s Fugitiv e dus t controls : Type : Spra

y Cyclon e Fab . Filte r Opacit yo f emission , % Scree n No . 1 2 3 4

THERMA L DRYE R

1 ; • \ Typ e Drye r fee d rate: . Drye r fee d size : Fee d moistur e content : Produc t moistur e content : Fa n loa d current : Fa n suctio n AP : Dryin g chambe r AP : Bt u Ratin g ton/h r .ton/hr

Flu e ga s temperatur e a t drye r exit : norma l (fo r las t 1 2 hrs . o f continuou s norma l operation ) Las t dat e o f temperatur e recorde r calibration : ampere s in , vac . in , vac . norma l maximu m minimu m o F o p

o p
Cyclon e outle t temperature: . Cyclon e AP : _°F in . (continued ) 3- 6

### Tabl e 8- 1 (continued

FLU E GA S SCRUBBE R Type : P.2 0

° Wate r suppl ypressur e (fo r las t 1 2 hrs . o f continuou s norma l operation ) 0 

### Pressur e los s a t scrubbe r (for las t 1 2 hrs . o f con tinuou s norma l operation ) Las t dat e o f recorde r calibration : Prescribe d frequenc yo f calibration : 0 

### Opacit yo f flu e ga s a t stac k exit , % Particulat e concentratio n a t exit , gr/dscf : n : it , qr / Norma l Maximu m Minimu m Norma l Maximu m Minimu m

% 'dscf : i n . i n . i n . i n . in . i n .



### CONVEYOR/TRANSFE R POINT S Drawa roug

hsketc ho f facilit ylayou t indicating an d num bering the conveyors , using the graphpape r o n following pag e Us e same number s t o identif ythe conveyor s i n the followinq table :

Locatio n Receivin g uni t Discharg e conveyo r width , in . Discharg e conveyo r speed , ft/min . Rate d capacity , ton/h r Loa d current , ampere s Typ e o f dus t control : spra y cyclon e fab . filte r Wate r press , in . Wate r flow , gp m Opacit yo f emission , % Conveyo r No . 1 2 3 4



### (continued ) 8- 7

### Tabl e 8- 1 (continued) . P.2 1

- r•— »

t•-. . , : •.

. . ...

„*.._. . ! I



### T

## T J . . •. i _. l

I' -

. l- • -~I—-• ' . tJ.. .

I• < • - * -•... .


# iI
,_. . . - - . , - -J I.- . , I

. i

; i i * !

! I

•- - 1 •I 1 ... I

1 . I 

### (continued ) 8- 8

_ J

### P.2 2

Tabl e 8- 1 (continued) . LOADIN G STATIO

N Typ e : I I Truc k I I Railroad I I Barg e

LJuni t Trai n L J Othe r Fee d capacit y Actua l fee d rate : ton/hr ton/hr Exten t o f dus t control : Fan loa d Current : [_ ] Goo d [_

] Poo r ampere s Typ e o f dus t control : I | Spray: Wate r suppl ypressur e in. , flowgp m I I Cyclone : Pressur e dro p in. , flow

_cf m I | Fabri c filte r : Pressur e dro p in . , flowcf m

Conditio n o f collecto r bag s Emissio n opacit y%
UNLOADIN

G STATION Type : I I Truc k I | Barg e I I Railroa d Fee d capacity : ton/hr Actua l feed rate : ton/hr Typ e o f Contro l device : I | Spray : Pressur e drop . I | Cyclone : Pressur e dro p Fabri c filter : Pressur e drop . in . , flowgp m in . , flowcf m in . , flowcf m Emissio n opacit y Conditio n o f collecto r bag s % 

### (continued ) 8- 9

### P.2 3

Tabl e 8- 1 (continued) . COAL STORAG E Typ e Osil o Location : 

# • Fabricate d Bi n Siz e o f coa l stored : _ Typ e o f coa l stored: _ Dus t contro l device : I I Spray Wate r suppl ypressur e I I Cyclon e Pressur e dro p I I Fabri c filte r Pressur e dro p Rawcoa l Washe d coa l

.in . , flow _gp

m

Fa n load curren t in. , flow . in. , flow amps . Conditio n o f collecto r bag s Storag e desig n feed rat e ton/hr Actua l fee d rat e ton/hr (continued ) cf m cf m

8-1 0 ' 'v i J

### P2A_



# u Tabl e 8- 1 (continued )

ADDITIONAL CHECK S DURIN G PERIODI C INSPECTIO N
RECORD S Weig hfeeder s Scrubbe r wate r suppl y Pressur e los s a t scrubbe r Drye r exi t ga s temperatur e SatisfactoryUnsatisfactory



# •• • • •D
COMMENT S O

NOPERATIONO F PLANT EQUIPMEN T BETWEE N TH E INSPECTION S

3-1 1

### P.2 5 \



### Th e frequenc yo f inspection s i s governe d b yagenc y policy . Aquarterl yinspectio n i s recommende d unles s com plaint s dictat e mor e frequen t inspections . Duratio n o f the inspectio n wil l depend o n the plan t layou t an

d numbe r o f emissio n sources ; usually , however , eac hplan t inspectio n require s 6 t o 8 hours . Thre e set s o f observation s ar e recommende d fo r eac hinspection . Majo r emphasi s o f th e inspectio n i s o n checkin g fa
cilit yrecord s an

d observin g th e operatio n o f proces s an d contro l equipment , including instrumentation . Th e following procedure s shoul d b e performe d i n the orde r show n wheneve r possible . Th e suggeste d forma t enable s th e inspecto r t o tou r th e plant , observ e th e process , an d monito r th e in
strument s durin g operation . Observation s Outsid e th e Plan t ° Not e plum e opacity . ° Chec k whethe r weighin g device s ar e properl y operating . Observation s Insid e th e Plan t ° Us e periodi c inspectio n checklis t (Tabl e 8-1 ) fo r recording proces s parameter s an d contro l equipmen t data . 0 

### Plan t record s o f therma l drye r exi t temperature , wate r suppl yt o th e scrubber , an d pressur e los s i n the scrubbe r provid e informatio n o n operation s durin g th e perio d betwee n inspections . Th e inspecto r shoul d b e satisfie d tha t th e record s ar e accurat e an d shoul d no t hesitat e t o as k fo r furthe r in
formation . 

# s

8-1 2

### P.2 6

8. 2 DETERMININ

G COMPLIANC E STATU S Complianc e statu s o f th e plan t i s determine d chiefl yb y comparin g th e inspectio n observation s wit hthos e obtaine d durin g performanc e test s an d previou s inspections . Althoug h suc hcomparison s d o no t allo wthe predictio n o f quantitativ e emissio n rates , theyd o serv e t o indicat e an yemissio n upsets . Understandin g th e significanc e o f eac hite m i n th e checklis t allow s th e inspecto r t o weig hthe effect s o f eac h itemo n proces s emissions . Th e relationship s o f checklis t item s wit hproces s emission s ar e discusse d below . Coa l Dat a Th e coa l moistur e conten t an d percentag e o f fin e coa l (-1/ 4 in. ) determin e th e loading s o f th e therma l drye r an d ai r tables . Highe r percentage s o f fin e coa l i n the feed ten d t o increas e therma l drye r emissions . Highe r moistur e conten t als o increase s the therma l drye r loading . I f the fee d analysi s differ s significantl yfro mthos e recorde d earlier , furthe r investigatio n shoul d b e made . Fee d Rat e I n general , the fee d rate s durin g periodi c inspection s shoul d no t b e highe r than thos e observe d durin g performanc e tests . An increas e i n feed rat e increase s the loading o f processin g equipment . Norma l fee d variation s u p t o 1 0 percen t mayno t significantl yaffec t the emissions . A n

8-1 3

### P.2 7

I 

### U

increas e i n fee d rate s shoul d b e compensate d fo r b y additiona l controls , suc ha s highe r flo wrate s fo r spray s an d highe r pressur e dro p acros s th e venturi . An yincreas e i n fee d rate s highe r tha n 1 0 percen t shoul d b e questioned . Load Curren t Th e preparatio n equipmen t generall yinclude s ammeter s tha t indicat e th e load current . Load curren t value s shoul d b e compare d wit hthos e observe d during performanc e tests . Overloadin g o f equipmen t wil l b e indicate d b yth e increas e i n demand o f load current . Fugitiv e Dus t Opacit y NSP S regulation s specif yth e opacit ylimit s fo r fugi
tiv e dus t emissions . Opacit yreading s according t o Metho d 9 shoul d b e take n t o determin e th e fugitiv e dus t emissio n compliance . Complianc e Actio n I f value s observe d i n a periodi c complianc e tes t indicat e tha t a citatio n i s warranted , th e inspecto r mus t clearl ystat e t o plan t official s the ground s fo r suc ha citation . A

n on-sit e citatio n i s justifie d onl yb yclear
cu t violations , suc ha s excessiv e opacit yo r failur e o f th e plan t t o maintai n o r provid e require d records .

8-1 4

### P.2 8

REFERENCE S 'X.,, Leonard , J.W . , an d D.R . Mitchel l (eds.) . Coa l Prepara tion . Thir d Edition . Ne wYork . Societ yo f Minin g Engineer s o f AIME . 1968 . 2 . Background Informatio n fo r Standard s o f Performance : Coa l Preparatio n Plants , Volum e 1 : Propose d Standards . U.S . Environmenta l Protectio n Agency , Researc hTriangl e Park , N.C . EPA-450/2-74-021a . Octobe r 1974 . 3 . Casey , J . Compilatio n o f Technica l Informatio n o n the Coa l Preparatio n Industry . U.S . Environmenta l Protec tio n Agency . Researc hTriangl e Park , N.C . (unpublished ) 4 . Background Informatio n fo r Standard s o f Performance : Coa l Preparatio n Plants , Volum e 2 : Tes t Dat a Summary . U.S . Environmenta l Protectio n Agency . Researc hTriangl e Park , N.C . EPA-450/2-74-0216 . Octobe r 1974 . 5 . Ai r Pollutan t Emissio n Factor s Supplemen t (TR W System s Group ) fo r U.S . Environmenta l Protectio n Agency . Researc hTriangl e Park , N.C . Contrac t No . CP A22-69
- 119 . Augus t 1970 . 6 . Compilatio n o f Ai r Pollutio n Emissio n Factors . Secon d Edition . U.S . Environmenta l Protectio n Agency . Researc hTriangl e Park , N.C . AP-42 . Apri l 1973 . 7 . Soderberg , H.E . Environmental , Energy , an d Economi c Consideration s i n Particulat e Control . Minin g Congres s Journa l 24-29 , Decembe r 1974 . 8 . Technica l Guid e fo r Revie wan d Evaluatio n o f Complianc e Schedule s fo r Ai r Pollutio n Sources . PEDCo-Environmenta l Specialists , Inc . fo r U.S . Environmenta l Protectio n Agency . Researc hTriangl e Park , N.C . EP AContrac t No . 68-02-0607 . Jul y1973 .

8-1 5

### P.2 9

APPENDI X A NE W SOURC E PERFORMANC E STANDARD S COAL PREPARATIONPLANT S

A- lP.3 0

223 2 RULES AN D REGULATION S

[FR L462-7 ] PAR T60—STANDARD S O F PERFORM - ANC E FOR NE

WSTATIONARYSOURCES Coa l Preparatio n Plants O nOctobe r

24 , 1974 (3 9 F R37922) . unde r secUo n11 1 o l th e Clea nAir Act , a s amended , th e Environmenta l Protec
- tio nAgenc y (EPA ) propose dstandard s o l perfonnanc e fo r

ne w an dmodifie d coa l preparatio nplants . Intereste dpar - tie s wer e afforde da nopportunit y t o par - ticipat e l nth e rulemakin g b y submittin g writte ncomments . Twenty-seve ncom - men t letter s wer e received ; si x fro mcoa l companies , fou r

fro mFedera l agencies , fou r fro mstee l companies , fou r fro m electri c utilit y companies , thre e fro m Stat e an dloca l agencies , thre e fro mcoa l Industr y association s an dthre e fro m othe r Intereste dparties . Copie s of th e commen t

letter s an da supplementa l volum e o

f backgroun dIn
- formatio nwhic hcontain s asummar y of th e comment s wit hEPA' s response s ar e availabl e fo r

publi c inspectio nan d copyin g a t

th e U.S . Environmenta l Pro
- tectio nAgency , Publi c Infonnatio nRef
erenc e Unit , Roo m2922 , 40 1 M Street , S.W. . Washington , D.C . 20460 . I naddi
- tion , th e supplementa l volum e o f back
- groun dinformatio nwhic hcontain s cop - ie s o f th e commen t

summar y wit hEPA' s response s ma y b e obtaine dupo nwritte n reques t fro mth e EP APubli c Informa
- tio nCente r

(PM-215) , 40 1 M Stree t aw. , Washington , D.C . 20460 (specif y Backgroun dInformatio nfo r Standard s of Performance : Coa l Preparatio n Plants , Volume 3 : Supplementa l Infor
- mation ) . Th e comment s hav e bee ncare - full y considered , an dwher e determine d b y th e Administrato r

t o b e appropriate , change s hav e bee nmad e t o th e propose d regulation s an dar e incorporate di nth e regulation s promulgate dherein . Th e base s fo r

th e propose dstandard s ar e presente dl n"Backgroun dInforma
- tio nfo r Standard s o

f Performance : Coa l Preparatio nPlants " (EP A450/2-74-02la , b) . Copie s of

thi s documen t

ar e avaUabl e o nreques t

fro mth e Emissio nStandard s Protectio nAgency . Researc hTriangl e an dEngineerin g Division , Environmenta l Park , Nort hCarolin a27711 , Attention : Mr . Do nR . Goodwin . Summaryof

Regulation. Th epromul
- gate dstandard s o

f performanc e regulat e particulat e matte r

emission s fro mcoa l preparatio nan dhandlin g facilitie s proc - essin g mor e tha n200 tons/da y o f bitu
- minou s coal (regardles s o f thei r location ) as follows : (1 ) emission s fro mtherma l dryer s ma y no t

excee d0.07 0 g/dsc m (0.03 1 gr/dscf) an d20 % opacity , (2 ) emission s fro mpneumati c coa l cleanin g equipmen t

ma y no t excee d0.^40 g/dsc m (0.01 8 gr /

dscf ) an d10 % opacity , an d (3 ) emission s fro mcoa l handlin g an d storag e equipmen t

(processin g non - bituminou s a s well a s bituminou s coal ) ma y no t excee d20 % opactity . Significant

Comments and

Revisions to the Proposed

Regulations. Man y o

f th e commen t letter s receive db y EPAcon - taine dmultipl e comments . Thes e ar e summarize da s foUow s withdiscussion s of an y significan t

difference s betwee nth e propose dan dpromulgate dregulations . 1 . Applicability. —Comments werere - ceive dnotin g tha t

th e propose dstand
- ard s woul dappl y t o an y coal handlin g operatio nregardles s o

f siz e an dwoul d requir e eve nsmal l tippl e operation s an d domesti c coal distributor s t o compl y wit h th e propose dstandard s fo r fugitiv e emissions . I naddition , undergroun d minin g activitie s ma y hav e bee ninad
- vertentl y Include dunde r th e propose d standards . EPAdi dno t inten dt o regu - lat e eithe r

thes e smal l source s o r

under
- groun dminin g activities . Onl y source s whic hbreak , crush , screen , clean , o r dr y larg e amount s o

f coa l wer e intende dt o b e covered . Source s whic hhandl e larg e amount s o

f coal woul dInclud e coa l han
- dlin g operation s a t

source s suc ha s barg e loadin g facUities , powe r plants , coke ovens , etc . a s we

Ua s plant s tha t

pri
- maril y clea nand/o r

dr y coal . EPAcon - clude dtha t

source s no t

Intende dt o b e covere db y th e regulatio nhandl e les s tha n20 0 tons/day ; therefore , th e regu - latio npromulgate dherei nexempt s suc h sources . Comment s wer e receive dquestionin g th e applicatio no

f th e standard s t o facilitie s processin g nonbttumlnou s coal s (includin g lignite) . A s was state dl nth e preambl e t o th e propose dregulation , i t I s intende dfo r

th e standard s t o hav e broa dapplicabilit y whe nappropriate . A t th e tim e th e regulatio nwas proposed , EP Aconsidere dth e parameter s relatin g t o th e contro l of

emission s fro mtherma l
FEDERA L REGISTER , VOL . 41 , NO . \0— THURSDAY, JANUAR Y15 , 197 6
A- 2

X_P.3 i
dryer s t o b e sufficientl y similar , whethe r bituminou s o r

nonbltuminou s coa l was bein g dried . Sinc e th e tim e of proposal , EP Aha s reconsidere dth e applicatio no f standard s t o th e therma l dryin g o f non bituminou s coal . I t

ha s conclude dtha t suc happlicatio ni s no t pruden t l nth e absenc e o f

specifl c dat ademonstratin g th e similarit y o

f th e dryin g character
istic s an demissio ncontro l character
istic s t o thos e o

f bituminou s coal . Ther e ar e currentl y very fe

w therma l dryer s o r pneumati c ai r

cleaner s processin g non bituminou s fuels . Th e facilitie s teste d b y EPAt o demonstrat e contro l equip
men t representativ e of

bes t contro l tech
nolog y were processin g bituminou s coal . Sinc e th e majorit y of

th e EPAtes t

dat a an dothe r

Informatio nuse dt o develo p th e standard s ar e basedupo nbituminou s coa l processing , th e particulat e matte r standard s fo r

therma l dryer s an dpneu mati c coa l cleanin g equipmen t hav e bee n revise dt o appl y onl y t o thos efacilitie s processin g bituminou s coal . Th e opacit y standar dfo r contro l of fugitiv e emission s i s applicabl e t o non bituminou s a s wel l a s bituminou s coal sinc e nonbltuminou s processin g facili
tie s wi UutUiz e simila r

equipmen t

fo r transporting , screening , storing , an d loadin g coal , an dth e contro l technique s applicabl e fo r

minimizin g fugitiv e par ticulat e matte r

emission s wi

Ub e th e sam e regardles s of

th e typ e of

coal proc essed . Typicall y enclosure s wit hsom e typ e o f lo w energ y collector s ar e utilized . Th e opacit y o

f emission s ca nals o b e re duce dby effectivel y coverin g o r sealin g th e proces s fro mth eatmospher es o tha t arty avenue s fo r

escapin g emission s ar e small . B y minimizin g th e numbe r an d th e dimension s o

f th eopening s throug h whic hfugitiv e emission s ca nescape , th e opacit y an dth e tota l mas s rat eo f emis
sion s ca nb e reduce dindependentl y o f th e ai r pollutio ncontro l devices . Also , wate r spray s hav e bee ndemonstrate dt o b e ver y effectiv e fo r

suppressin g fugitiv e emission s an dca nb e use dt o contro l eve n th e mos t difficult fugitiv eemissio nprob
lems . Therefore , th e contro l o f fugitiv e emission s a t

al l facilitie s wil l b e require d sinc e ther e ar esevera l contro l technique s tha t ca nb e applie dregardles s o f th e typ e of coal processed . 2 . Thermal

dryer standard. —One com mentato r presente ddat aan dcalcula
tion s whic hIndicate dtha t becaus eof

th e larg e amoun t

o f fine particle s i nth ecoal hi s compan y processes , complianc ewit h th e propose dstandar dwoul drequir e th e applicatio no

f aventur i scrubbe r

wit h apressur e dro p o

f 5 0 t o 5 2 inche s of

wate r gage . Th e propose dstandar dwa abase d o nth e applicatio np

f aventur i scrubbe r wit hapressur e dro p o

f 25 t o 3 5 Inches . EP Athoroughl y evaluate dthi s commen t an dconclude dtha t

th ecommentator' s calculation s an dextrapolation s coul d hav e represente dth eactua l situation . Rathe r tha nrevis e th estandar do nth e basi s of th e commentator' s estimates , EPAdecide dt o perfor memissio ntest s a t aplan t whic hprocesse s th e coa l unde r question . Th e plan t

teste dl s controlle d wit haventur i scrubbe r

an dwas operate d a t apressur e dro p of

29 Inche s durin g RULE S AN D REGULATION S th e emissio ntests . Thes e test s showe d emission s o

f 0.080 t o 0.13 4 g/dsc m(O.03 5 t o 0.05 8 gr/dscf) . Thes e result s ar e numericall y greate r

tha nth e ^propose d standard ; however , calculation s Indicat e tha t I f th e pressur e dro p wer e increase d fro m2 9 inche s t o 4 1 inches , th e propoSe d standar dwoul db e achieved , Supplemen
ta l Informatio nregardin g estimate s o f emissio ncontro l neede dt o achiev e th e mas s standar dI s containe dl nSectio nII , Volum e 3 of

th e supplementa l back
groun dinformatio ndocument . Sinc e th e cos t

analysi s o

f th e propose d standar dwas basedo naventur i scrubbe r operatin g a t

25 t o 3 5 inches.ventur i pres sur e loss , th e cost s o

f operatin g a t

highe r pressur e losse s wer e evaluated . Thes e re sult s Indicate dtha t

th e adde dcos t

of controllin g pclhitant s t o th e leve l of th e propose dstandar dI s onl y 1 4 cent s pe r to no f plan t produc t eve nlf a5 0 Inc h pressur e los s wer e used , an donl y Av e cent s pe r to ni nexces s o

f th e averag e contro l leve l require db y stat e regulation s i nth e majo r

coal producin g states . I n compariso nt o th e $18.95 , pe r to ndeliv
ere dpric e o

f U.S . coa l I n197

4 an deve n highe r price s today , amaximu mfive cent s pe r to neconomi c Impac t

attribut
abl e t o thes e regulation s appear s almos t negligible . Th e tota l Impac t o f 14 cent s pe r to nfor controllin g particulat e matte r emission s ca neasil y b e passe dalon g to th e custome r

sinc e th e deman dfo r therma l dryin g du e t o freigh t Tat e sav ings , th e eliminatio no

f handlin g prob
lem s du e t o freezing , an dth e need s o f th e customer' s proces s (coke oven s mus t contro l bul k

densit y an dpowe r

plant s mus t contro l pluggin g o

f pulverizers ) will remai nunaffecte db y thes e regulations . Therefore , th e economi c Impac t o f th e standar dupo ntherma l dryin g wil l no t b e larg e an dth e inflationar y impac t o f th e standar do nth e pric e o f coal wil l b e insignifican t

(on e percen t

o r less) . Fro m th e standpoin t

o f energ y consumption , th e powe r

requirement s o

f th e ai r pollu
tio ncontro l equipmen t

ar e exponentiall y relate dt o th e contro l leve l suc htha t a leve l o f diminishin g retur ni s reached . Becaus e th e highes t

pressur e los s tha t ha s bee ndemonstrate db y operatio no f aventur i scrubbe r

o nacoa l drye r

i s 4 1 inche s wate r

gage , whic hI s als o th e pressur e los s estimate db y ascrubbe r vendo r t o b e neede dt o achiev e th e 70 mg/dsc mstandard , an dbecaus e energ y consumptio nIncrease s dramaticall y a t lower contro l level s (<7 0 mg/dscm) , a particulat e matte r

standar dlowe r

tha n 70 mg/dsc mwas no t

selected . A t

th e 70 mg/dsc mcontro l level , th e trade-of f be
twee ncontro l of

emission s a t

th e therma l drye r versu s th e Increas e l nemission s a t th e powe r

plan t supplyin g th e energ y l s favorabl e eve nthoug hth e mas s quantit y o f al l ai r pollutant s emitte db y th e powe r plan t (SO> . NO. , an dparticulat e matter ) ar e compare donl y t o th e reductio nI n therma l drye r

particulat e matte r

emis
sions . A t lowe r tha n70 mg/dscm , thi s trade-of f I s no t a s favorabl e du e t o th e energ y requirement s o

f ventur i scrubber s a t highe r pressur e drops . Fo r

thi s source , alternativ e mean s of

ai r pollutio ncontro l hav e no t bee nfully demonstrated . Hav
in g considere dal l comment s o nth e par 223 3 tlculat e matte r

regulatio npropose dfo r therma l dryers , EPAfind s n o reaso nsuf
ficien t t o alte r th e propose dstandar do f 7 0 mg/dsc mexcep t

t o restric t

it s ap pUcabillty t o therma l dryer s processin g bituminou s coal . 3 . Location of

thermal drying systems. —Comments wer e receive do nth e applicabilit y o

f th e standar dfo r

powe r plant s wit hclose dtherma l dryin g sys tem s wher e th e ai r

use dt o dr y th e coa l l s als o use di nth e combustio nprocess . A s Indicate dl nj 60.252(a) . th e standar di s concerne donl y wit heffluent s whic har e discharge dint o th e atmospher e fro mth e dryin g equipment . Sinc e th e pulverize d coal transporte dby heate dai r l s charge d t o th e stea mgenerato r

i naclose dsystem , ther e I s n o discharg e fro mth e drye r di
rectl y t o th e atmosphere , therefore , thes e standard s fo r

therma l dryer s ar eno t

ap plicable . Effluent s fro mstea mgenerator s ar e regulate db y standard s previousl y promulgate d(4 0 CF RPar t 60 subpar t D) . However , thes e standard s do appl y t o al l bituminou s coa l dryin g operation s tha t discharg e effluent

t o th e atmospher e regardles s of

thei r physica l o r

geograph
ica l location . I naddltton at o therma l dryer s locate dI ncoa l preparatio nplants , usuall y l nth e vicinit y of the'mlnes , dry
er s use dt o prehea t

coa l a t cok e oven s ar e alsorcgulate db y thes estandards . Thes e coke ove ntherma l dryer s use dfo r pre heatin g ar e simila r

I nal l respects , in
cludin g th e ai r

poll u yo ncontro l equip
ment , t o thos e use dl ncoa l preparatio n plants . 4 . Opacitystandards. —The opacit y standard s fo r

therma l dryer ' an dpneu mati c coal cleaner s wer e reevaluate da s aresul t of revision s t o Metho d9 fo r con ductin g opacit y observation s (3 9 F R 39872) . Th e opacit y stndard s wer e pro pose dprio r

t o th e revision s o

f Metho d9 an dwer e no t

base dupo nth e concep t o f averagin g set s o

f 2 4 observation s fo r

six
minut e periods . As aresult , th e propose d standard s wer e develope dI nrelatio nt o th e pea k emission s of

th e facility rathe r tha nth e averag e emission s o f six-minut e periods . Th e opacit y dat acoUecte db y EP Ahav e bee nreevaluate di naccordanc e wit hth e revise dMetho d9 procedures , an dopacit y standard s fo r therma l dry
er s an dpneumati c coa l cleaner s hav e bee nadjuste dt o level s consisten t wit h thes e ne w procedures . Th e opacit y stand
ard s fo r therma l dryer s an dpneumati c coal cleaner s hav e bee nadjuste dfro m3 0 an d20 percen t

t o 2 0 an d1 0 percen t opacity , respectively . Sinc e th e propose d standard s wer e base dupo npeak rathe r tha naverag e opacity , th e revise dstand
ard s ar e numericall y lower . Eac hof thes e level s l s Justifie dbase dprimaril y upo n slx-mlnut e average s of

EPAopacit y ob
servations . Thes e dat aar e containe di n Sectio nIH . Volum e 3 of

th e supplementa l backgroun dInformatio ndocument . 5 . Fugitive '

emission monitoring.—• Severa l commentator s identifie dsom e difficultie s wit hth e propose dprocedure s fo r monitorin g th e surfac e moistur e o f thermall y drie dcoal . Th e purpos e of th e propose drequiremen t

wa at o determin e th e probabilit y o

f fugitiv eemission s oc curin g fro mcoal handlin g operation s FEDERA L REGISTER , VOL . 41 , NO . 10—THURSDAY , JANUAR Y15 , 1.97 6

A- 3P.3 2

223 4 an dt o estimat e thei r

extent . Th e com mentator s note dtha t th epropose d A.S.T.M . measuremen t

method s ar ediffi
cul t an dcumbersom e procedure s no t typicall y use db y operatin g faculties . Also , i t was note dtha t

ther e l s to o littl e uniformit y o

f technique s withi nIndustr y fo r measurin g surfac e moistur e t o spe cif y agenera l method . Secondly , esti
matio no f fugitiv e emission s fro msuc h dat ama y no t

b e consisten t

du e t o differ
en t coal characteristics . Sinc e th eopac it y standar dpromulgate dherei nca n readil y b e utilize db y enforcemen t per sonnel , th e moistur emonitorin g require
men t l s relativel y unimportant . EPAha s therefor e eliminate dthi s requiremen t fro mth e regulation : 6. Open storage piles. —Theproposed regulatio napplie dth efugitiv e emissio n standar dt o coa l storag e systems , whic h wer e define da s an y facult y use dt o stor e coal . I t wa s EPA' s Intentio ntha t thi s definitio nrefe r

t o som etyp e of

structur e suc ha s abin , silo , etc . Severa l com mentator s objecte dt o th e potentia l ap plicatio nof

th e fugitiv e emissio nstand
ar dt o ope nstorag e piles . Sinc e th e fugitiv e emissio nstandar dwas no t de
velope dfo r

applicatio nt o ope nstorag e piles , th e regulation s promulgate dhere
i nclarifie s tha t

ope nstorag e pile s of

coa l ar e no t regulate db y thes e standards . 7 . Thermal

dryer monitoring equip ment.

— Anumbe r

of commentator s fel t tha t Importan t

variable s wereno t

bein g oonsldere dfo r

monitorin g ventur i scrub
be r operatio no ntherma l dryers . Th e propose dstandard s require dmonitorin g th e temperature o

f th e ga s fro mth e therma l drye r

an dmonitorin g th e ventur i scrubbe r

pressur e loss . Th e promulgate dstandar drequires , l naddi
tio nt o th e above parameters , monitor
in g o f th e wate r

suppl y pressur e t o th e ventur i scrubber . Direc t measuremen t of th e wate r

flow rat e was considere d bu t rejecte ddu e t o potentia l pluggin g problem s a s aresul t

o f solid s typicall y foun di nrecycle dscrubbe r water . Also , th e highe r

oos t of aflow rat e mete r

l n compariso nt o asimple r pressur e moni
torin g devlo e was afacto r i ntii e selec
tio nof awate r

pressur e monito r

fo r verifyin g tha t

th e scrubbe r

receive s ade
quat e wate r

fo r prope r operation . Thi s revisio nt o th e regulation s wil l Insur e monitorin g o

f majo r ai r pollutio ncontro l devic e parameter s subjec t t o variatio n whic hcoul dg o undetecte dan dunnotice d an dcoul dgrossl y affec t prope r opera tio nof th e contro l equipmen t

Apressur e sensor , tw o transmitters , an datw o pe n char t recorde r fo r monitorin g scrubbe r ventur i pressur edro p an dwate r suppl y pressure , whic har e commerciall y avaU
able , will oos t

approximatel y tw o t o thre e thousan ddollar s Installe dfo r eac h therma l dryer . Thi s cos t l s onl y one tent hof on e percen t

o f th e tota l Invest
men t cos t of a500-ton-per-hou r

therma l dryer . Th e regulation s als o requir e moni
torin g o f th e therma l drye r

exi t tem perature , bu t

n o adde dcos t

wi Uresul t becaus e thi s measuremen t syste ml s normall y suppUe dwit hth etherma l dry
in g equipmen t

an dl s use da s acontro l poin t fo r th e proces s contro l sysiem . RULES AN D REGULATION S Effective date.-'

Inaccordanc e wit h sectio n11 1 o f

th e Act , a s amended , thes e regulation s prescribin g standard s o f performanc e fo r

coa l preparatio nplant s ar e effectiv e o nJanuar y 15 , 1976 , an d appl y t o therma l dryers , pneumati c coal cleaners , coa l processin g an dconveyin g equipment , coa l storag e systems , an d coal transfe r

an dloadin g systems , th e constructio no r

modificatio nof

whic h was commence dafte r

Octobe r 24 , 1974 . Dated : Januar y 8 , 1976 .

RUSSEL LE . TRAIN , administrator . Par t 6 0 of Chapte r Io f Titl e 4 0 o f th e Cod e of Federa l Regulation s I s amende d a s follows : 1 . Th e tabl e o

f content s l s amende db y addin g subpar t

Ya s follows : Subpar t Y—Standard a o

fPerform s ne t fo rCoa l Preparatio n plant s Sec . 60. 2 6 0 60.26 1 60.2S 3 60.25 3 60.26 4 Applicabilit y an d dealgnatlo no f

afTecte d facility . Definitions . Standard s fo rparticulat ematter . Monitorin go f

operations . Tee tmethod s an d procedures . A-oTKOKrrT : Sees . 11 1 an d 11 4 o f th eClea n Ai rAce , as-amende d b y sec . 4(a ) o f Pu-i . L . 91-604 , to Stat . 167 8 (4 2 0.S.C . 1857&-6 , 186 7 C-B) . 2 . Par t 60 l s amende dby addin g sub
par t Ya s follows : •* * e • Subpar t Y—Standard s ofPerformanc e fo r Coa l Preparatio n Plant s § 60.25 0 Applicabilit yan d designatio n o faffecte d facility . Th e provision s of

thi s subpar t

ar e applicabl e t o an y of

th e followin g af

fecte dfacilitie s i ncoa l preparatio nplant s whic hproces s mor e tha n20 0 ton s pe r day : therma l dryers , pneumati c coal
cleanin g equipmen t

(ai r tables) , coa l processin g an dconveyin g equipmen t (In
cludin g breaker s an dcrushers) , coal storag e systems , an dcoal transfe r an d loadin g systems . § 60.25 1 D*6nitions . As use dl nthi s subpart , al l term s no t denne dherei nhav e th e meanin g given the ml nth e Ac t

an dl nsubpar t

Aof thi s part . (a ) "Coa l preparatio nplant " mean s an y facilit y (excludin g undergroun d minin g operations ) whic hprepare s coa l b y on e o r

mor e o f th e followin g proc esses : breaking , crushing , screening , we t o r dr y cleaning , an dtherma l drying . <b) "Bituminou s coal " mean s soli dfos
si l fue l classifie da s bituminou s coa l b y A.8.T.M . Designatio n73-388-66 . (c ) "Coal " mean s al l soli dfossi l fuel s classifle da s anthracite , bituminous , sub
bituminous , o r

lignit e b y AJB.T.M . Des
ignatio nD-388-66 . (d ) "Cycloni c flow" mean s asplralln g movemen t

o f exhaus t gase s withi naduc t o r stack . (e ) "Therma l dryer " mean s an y fa
cilit y l nwhic hth e moistur e conten t o f bituminou s coa l I s reduce db y contac t wit haheate dga s strea mwhic hi s ex hauste dt o th e atmosphere . (f ) "Pneumati c coal-cleanin g equip
ment " mean s an y facilit y whic hclassifie s bituminou s coa l b y siz e o r separate s bi
tuminou s coa l fro mrefus e b y applicatio n o f at r stream(s) . (g ) "Coa l processin g an dconveyin g equipment " mean s an y machiner y use d t o reduc e th e siz e o

f coa l o r t o separat e coa l fro mrefuse , an dth e equipmen t use d t o conve y coa l t o o r

remov ecoal an d refus e fro mth e machinery . Thi s In
cludes , bu t

l s no t limite dto , breakers , crushers , screens , an dconveyo r belts . (h ) "Coa l storag e system " mean s an y facilit y use dt o stor e coal excep t fo r ope n storag e piles . (1 ) "Transfe r

an dloadin g system " mean s an y facilit y use dt o transfe r an d loa dcoa l fo r

shipment . § 60.25 2 ter . Standard s fo rparticulat e mal - (a ) O nan dafte r

th edat eo nwhic h th e performanc e tes t

require dt o b e con ducte db y j 60. 8 i s completed , a nowne r o r operato r

subjec t t o th e provision s o

f thi s subpar t

shal l no t

caus e t o be , dis
charge dmt o th e atmospher efro man y therma l drye r

gase s which : <1 ) Contai nparticulat e matte r i nex ces s o f 0.07 0 g/dsc m(0.03 1 gr/dscf) . '2 > Exhibi t

20 percen t

opacit y o r greater . (b > O nan dafte r

th e dat e o nwhic hth e performanc e tes t

require dt o b e con ducte db y %60. 8 I s completed , a nowne r o r operato r subjec t t o th eprovision s of thi s subpar t

shal l no t

caus e t o b e dis
charge dInt o th e atmospher e fro man y pneumati c coa l cleanin g equipment , gase s which : (1 ) Contai nparticulat e matte r i nex ces s of 0.040 g/dsc m(O.O

Ugr/dscf) . (2 ) Exhibi t

1 0 percen t

opacit y o r greater . ' (c ) O nan dafte r

th e dat e o nwhic h th s performanc e tes t

require dt o b econ ducte db y I60. 8 I s completed , a nowne r o r operato r subjec t t o th eprovision s o

f thi s subpar t

shal l no t

caus e t o b e dis
charge dInt o th e atmospher efro man y coa l processin g an dconveyin g equip
ment , coa l storag e system , o r coa l trans fe r an dloadin g syste mprocessin g coal . gase s whic hexhibi t

20 percen t

opacit y o r greater , § 60.25 3 Monitorin go f operations . (a ) Th e owne r

o r operato r o f an y ther
ma l drye r

shal l Install , calibrate , main
tain , an dcontinuousl y operat e monitor
in g device s a s f

oDows : (1 ) Amonitorin g devlo e fo r th emeas uremen t o f th e temperatur e o

f th ega s strea ma t

th e exi t of th etherma l drye r o nacontinuou s basis . Th e monitorin g devic e I s t o b e certifie db y th e manu facture r t o b e accurat e within * 3 * Fahr
enhei t (2 ) Fo r affecte dfacilitie s tha t

us e ven tur i scrubbe r

emissio ncontro l equip
ment : (1 ) Amonitorin g devic e fo r th e con tinuou s measuremen t

of th e pressur e los s throug hth e ventur i constrictio no f th e FEDERA L IEGISTER , VOL . 41 , NO . 10—THUBSOAY , JANUAI Y15 , 197 6

A- 4contro l equipment . Th e monitorin g de
vic e l at o b ecertifie dby th e manufac
ture r t o b e accurat e withi n±1 Inc h wate r gage . (11 ) Amonitorin g devic e fo r th e con tinuou s measuremen t

of th e wate r

sup pl y pressur et o th e contro l equipment . Th e monitorin g devic el s t o b e certifie d b y th e manufacture r

t o b e accurat e with
i n± 5 percen t

o f desig nwate r

suppl y pressure . Th e pressur e senso r o r ta p mus t b e locate dclos e t o th e wate r discharg e point . Th e Administrato r ma y b e con sulte dfo r

approva l of

alternativ e loca
tions . (b ) All monitorin g device s unde r para grap h(a ) of

thi s sectio nar e t o b e recali
brate dannuall y I naccordanc e wit hpro cedure s unde r

S 60.13(b ) (3 ) o

f thi s part . § 60.25 4 Tea t method s an d procedures . (a ) Th e referenc e method s l nAp
pendi x Ao f

thi s part , excep t

a s provide d l nj 60.8(b) , ar e use dt o determin e com plianc e wit hth e standard s prescribe dl n > 5 60.25 2 a s follows : (1 ) Metho d5 fo r

th e concentratio no

f

. particulat e matte r

an dassociate dmois
tur e content , (2 ) Metho d1 fo r

sampl ean dvelocity traverses , (3 ) Metho d2 fo r

velocity an dvolu
metri c flow rate , an d (4 ) Metho d3 fo r

ga s analysis . -(b ) Fo r Metho d5 , th e samplin g tim e fo r eac hru nl s a t

leas t 60 minute s an d th e minimu msampl evolum e l s 0.8 5 dsc m (3 0 dscf ) excep t tha t shorte r samplin g time s o r smalle r volumes , whe nnecessi
tate db y proces s variable s o r othe r fac
tors , ma y b e approve db y th e Adminis
trator . Samplin g l s no t

t o b estarte dunti l 3 0 minute s afte r

start-u p an dl s t o b e terminate dbefor eshutdow nprocedure s commence . Th e owne r

o r operato r of th e affecte dfacilit y shal l eliminat ecycloni c flow durin g performanc etest s l naman ne r acceptabl e t o th e Administrator . (c ) Th e owne r

o r operato r shal l con struc t th e facilit y s o tha t

particulat e emission s fro mtherma l dryer s o r pneu mati c coa l cleanin g equipmen t ca nb e accuratel y determine db y applicabl etes t method s an dprocedure s unde r para grap h(a ) o

f thi s section . (F RDQC.10-124 0File d 1-14-70:8:4 5 am ] ~ ~ —— P,33 _ RULES AN D REGULATION S 220 5

FEDERA L REGISTER

, VO L 41 . NO . IO—THURSDAYJANUARY13 , 197 4 A- 5

### P.3 4

APPENDI X B STANDARD TES T METHOD S

B- lP.3 5

Appendi x A—Referenc e Method s

. ! i I' • METHO D 1—SAMPL E AN D VELOCITY TRAVEB5E 3 TORBTATIOr-rAR

Y SOUBCE 3 1 . Principle and

Applicability. 1. 1 Principle . Asamplin g Bit e an dth e numbe r of travers e point s ar e selecte dt o ai d l nthe.extractio nof

arepresentativ e sample . 1. 2 Applicability . Thl B metho dshoul d b e applie donl y whe nspecifie db y th e tes t procedure s fo r

determinin g complianc e wit h th e New Sourc e Performanc e Standards . Un
les s otherwis e specified , thi s metho dI B no t Intende dt o appl y t o ga s stream s othe r tha n thos e emitte ddirectl y t o th e atmospher e withou t furthe r processing . 2 . Procedure. 2. 1 Selectio nof

asamplin g sit e an dmini
mu mnumbe r

of travers e points . 2.1. 1 Selec t

asamplin g sit e tha t

t s a t leas t eigh t stac k o r duc t diameter s downstrea m an dtw o dlameter B upstrea mfro man y no w disturbanc e suc ha s abend , expansion , con traction , o r

visibl e name . Fo r

rectangula r cros s section , determin e a nequivalen t diam
ete r fro mth e followin g equation :

• i * . J * . „/(length ) (width ) \ equivalent diameter= 2 -^—-, . , • _,, . )

V length+width/ 1 equatio n1- 1 2:i.2 ; Whe nth e abov e samplin g sit e criteri acan.b e met , th e minimu mnumbe r of travers e point s l s twelv e (12) . 2.1. 3 Som e samplin g situation s rende r th e • abov e samplin g sit e criteri aimpractical . Whe nthi s I s th e case , choos e aconvenien t samplin g locatio nan dus e Figur e 1- 1 t o de
termin e th e minimu mnumbe r of travers e points . Unde r

n o condition s shoul dasam plin g poin t

b e selecte dwithi n1 Inc hof th e stac k wall . T o obtai nth e numbe r o f travers e point s fo r

stack s o r

duct s wit hadiamete r les s tha n2 feet , multipl y tb e numbe r of point s obtaine dfro mFigur e 1- 1 b y 0.87 . 2.1. 4 T o us e Figur e J- l firs t measur e th e distanc e fro mth e chose nsamplin g locatio n t o th e neares t

upstrea man ddownstrea mdis
turbances . Determin e th e correspondin g numbe r of travers e point s fo r

eac hdistanc e fro mFigur e 1-1 . Selec t th e highe r

of th e tw o number s of

travers e points , o r

agreate r value , suc htha t

fo r circula r stack s th e num be r i s amultipl e of

4 . an dfo r

rectangula r stack s th e numbe r

follow s th e criteri ao f sectio n2.2.2 . 2. 2 Cross-sectiona l layou t an dlocatio nof travers e points . 2.2. 1 Fo r

circula r

stack s locat e th e tra vers e point s o na t

leas t tw o diameter s ac cordin g t o Figur e 1- 2 an dTabl e 1-1 . Th e travers e axe s shall ' divid e th e stac k cros s sectio nInt o equa l parts . 2.2. 2 Fo r

rectangula r

stack s divid e th e cros s sectio nInt o a s man y equa l rectangula r area s a s travers e points , suc htha t th e rati o o f th e lengt ht o th e wldll : o f th e elementa l area s l abetwee no man dtwo . Locat e th e travers e point s <v

t th e centroi dof

eac hequa l area-acoordln g o Figur e 1-3 . 3 . Reference!. Determinin g Dus t

Concentratio nI naCns Stream , ASMEPerformanc e Tes t Cod e -27 , New York , N.Y. . 1957 . Devorkln . Howard , e t al. . Air

Poll u lio n Sourc e Testin g Manual . Air Pollutio nContro l District . Lo s Angeles . Calif . Novembe r 1963 . Method s fo r

Determinatio nof

Velocity . Volume . Dus t

an dMis t

Conten t

of Gases , Wester nPrecipitatio nDivisio nof Jo y Manu
facturin g Co. , Lo s Angeles , Calif. Bulleti n WP-50 . 1968 . Standar dMetho dfo r Samplin g Stack s fo r Particulat e Matter . In : 197 1 Boo k of ASTM Standards , Par t

23 . Philadelphia , Pa . 1971 . ASTM Designatio nD-2328-71 . NUMBE R O F DUC TDIAMETER S UPSTREAM ' [DISTANCE A t 2. 5 ,XI7DISTUHBANC E

. SAMPLIN Q "SIT E

DISTURBANC E

•FfiO M POIN TO F AN YTYP E O F DISTURBANC E (BEND , EXPANSION , CONTRACTION . ETC. )
»

NUMBE R O F DUCT-DIAMETER S DOWNSTREAM *

(DISTANC E B )
Figur eW . Minimu

mnumber o f travers epoints .

Figur e 1-2 . Cros s sectio n ofcircula rstac k divide d int o 1 2 equal areas , sho.vin g locatio n oftravers e point s a t centroi d o feac h area .

x B- 2P.3 6
Tabl e 1-1 . Locatio n o ftravers e point s i n circula rstack s (Percen t o fstac k

diamete rfro m insid e wal l t o travers e point ) Travers e poin t numbe r diamete r 1 2 3 4 5 6 7 8 9 1 0 1 1 12 1 3 14 1 5 1 6 17 I B 1 9 2 0 2 1 2 2 2 3 24 2 14. 6 85. 4 4 i.i 25. 0 75. 0 93. 3 Numbe r o f travers e point s 6 4. 4 14. 7 29. 5 70. 5 85. 3 95. 6 8 3. 3 10. 5 19. 4 32. 3 67. 7 80.6 89. 5 96. 7 10 2. 5 8. 2 14. 6 22. 6 34. 2 65. 8 77. 4 85. 4 91. 8 97. 5 1 2 2. 1 6. 7 11. 8 17. 7 25. 0 35. 5 64. 5 75. 0 82. 3 88.2 . 53. 3 97. 9 1 4 1. 8 5. 7 9. 9 14. 6 20. 1 26. 9 36. 6 63. 4 73. 1 79. 9 85. 4 90. 1 94. 3 98. 2 o na diamete r 1 6 1. 6 4. 9 8. 5 12. 5 16. 9 22. 0 28. 3 37. 5 62. 5 71. 7 78. 0 83. 1 87. 5 91. 5 95. 1 98. 4 1 8 1. 4 4. 4 7. 5 10. 9 14. 6 18. 8 23. 6 29. 6 38. 2 61. 8 70. 4 76. 4 81. 2 85. 4 09. 1 92. 5 95. 6 93. 6 2 0 1. 3 3. 9 6. 7 9. 7 12. 9 16. 5 20. 4 25. 0 30. 6 38. 8 61. 2 69. 4 75. 0 79. G 83. 5 87. 1 90. 3 93. 3 96. 1 98. 7 22 1. 1 3. 5 6. 0 8. 7 11. 6 14. 6 18. 0 21. 8 26. 1 31. 5 39. 3 60. 7 68. 5 73. 9 70. 2 82. 0 05. 4 83. 4 91. 3 94. 0 9C. 5 9B. 9 .2 4 1. 1 .3. 2 5. 5 7. 9 10. 5 13. 2 16. 1 |9. 4 23. 0 27. 2 32. 3 39. 8 60. 2 67. 7 72. 8 77. 0 80.6 83. 9 86. 8 09. 5 92. 1 94. 5 96. 8 98. 9

I t • I I 1 o | o . . 9 | o

1 i 1 _ « . ' t _i ! ii O | O | O I o I I • I I I

—rT ! ' * O | o t o 1 o < I I 1 ' I Figur e 1-3 . Cros s sectio n o frectangular'stac k divide d int o 1 2 equa l areas , wit h travers e point s a t centroi d o feac h area .

B- 3P.3 7

METHO D J—DETERMINATIO NO r STAC K

CA S VELOCIT Y AN D VOLUMETRI C TLOWHAT E(TYT E S PITO T TUBE ) 1 . Principl e and

applicability. 1. 1 Principle . Stac k ga s velocit y l s deter
mine drro mth e ga s densit y an dfio mmea.s uremen t

o f th e velocit y hea dusin g aTyp e S (Stauschelb e o r

revers e type ) pito t tube . l. aApplicability . Thi s metho dshoul dli e applie donl y whe nspecifie db y th e tes t pro - cedure s fo r

determinin g complianc e wit hth e Ne w Sourc e Performanc e Standards . 2 . Apparatus. 2. 1 Pito t

tube—Typ e S (Figur e 2-1) , o r equivalent , wit hacoefficien t withi n±5 % ove r th e workin g range . 2. 2 Differentia l pressur e gauge—Dicllnc d manometer , o r

equivalent , t o measur e velo
cit y hea dt o withi n10 % o f th e minimu m value . 2. 3 Temperatur e gauge—Thermocoupl e o r equivalen t

attache dt o th e pito t tub e t o measur e stac k

temperatur e t o withi n1.5 % o f t h e minimu mabsolut e stac k temperature . 2. 4 Pressur e gauge—Mercury-fiile dU-tub e manometer , o r

equivalent , t o measur e stac k pressur e t o withi n0. 1 In . Hg . 2. 5 Barometer—T o measur e atmospheri c pressur e t o withi n0. 1 In . Hg .

- 2, 6 Ga s analyzer—T o analyz e ga s composl
- • tlo nfo r

determinin g molecula r weight . 2. 7 Pito t

tube—Standar dtype , t o cali
brat e Typ e S pito t

tube . * 3 . Procedure. 3. 1 Se t

u p th e apparatu s a s show ni nFig
u r e 2-1 . Mak e sur e al l connection s ar e tigh t a n dlea k

free . Measur e th e velocit y hea dan d temperatur e a t

th e travers e point s specifie d b y Metho d1 . 3. 2 Measur e th e stati c pressur e i nth e stack . 3. 3 Determin e th e stac k ga s molecula r weigh t b y ga s analysi s an dappropriat e cal
culation s a s indicate dI nMetho d3 . 4 . Calibration. 4. 1 T o calibrat e th e pito t tube , measur e t h e velocit y hea da t som e poin t

I naflowin g ga s strea mwit hbot haTyp e S pito t tub e an d astandar dtyp e pito t tub e wit hknow nco efficient . Calibratio nshoul db e don e i nth e laborator y an dth e velocit y o f th e flowin g g;>--

5 strea mshoul db e varie dove r th e norma l workin g range . I t

l s recommende dtha t th e calibratio nb e repeate dafte r us e a t eac hfiel d site . 4. 2 Calculat e th e pito t tub e coefficien t usin g equatio n2-1 . C =C A-M'. m V aiv. i equatio n--- 1 where : C», P . , = Plto t

tub e coefficien t

o f Typ e S pito t tube . Cp, t J =-Pito t

tub e coefficien t

o f standar d typ e pito t

tub e (l f

unknown , us e 0.9 9 j . -lp,id = Velocit y hea dmeasure db y stand
-

ar dtyp e pito t

tube , dpi.« i = Velocit y hea dmeasure db y Typ e S

pito t tube . 4. 3 Compar e th e coefTlclen Uo f th e Typ e S plbo t tub e determine dfirs t wit hon e le g an d the nth e othe r

pointe ddownstream . Us e th e pito t tub e onl y i f

th e tw o coefficient s diffe r b y n o mor e tha n0.01 . 5 . Calculations. Ds e equatio n2- 2 t o calculat e th e stac k ga s velocity . Equatio n2- 2 where : (V,).., , = Slac k

RM velocity . W l pe r

secon d(f.i'.s.) . K D -=8fi.*JR—(--—.'.•_ . J"whe nthos e ••• l u s

sec.Vlb . mole
- 11 / ore used . (-',.-= I'llo t

lub e cnefliiii'tit , rthncnslonless. (T.l,„.HAverag eabsolut e stac k gii s Iciiiiicr-i.hire , "R . vivac e velocity lieai l o

f stac k c:is , Indir a Hl O (Se e Fiji . 2-2) . !' , = Absolut e Stack

pa s pressure , Indie s Up . M,- aMolecula

r weigh t o f stac k ga s (we t l.msis) , 11>./lb.-mole . Md(l-H. D )+!Rn. n M d= Pr y molecular

wigh t o f stac k j-n s (from Metiio d3) . B.o=Pi'oiwlio nb y volume , o f wate r i*n|>o f I n th e ca s strea m(fromMetho d4) . Figur e 2- 2 show s asampl e recordin g shee t fo r velocit y travers e data . Us e th e average s l nth e las t

tw o column s o f

Figur e 2- 2 t o de
- termin e th e averag e stac k ga s velocit y fro m Equatio n2-2 . Us e Equatio n2- 3 t o calculat e th e stac k ga s volumetri c flow rate . Q.- M oo(i-B„)v.A( r T;--)( ] |; t ) Equatio n2-? i where : Q.=Voliinietik
- fhtu
- rale , dt y basis , standar dcondi
tions , ft.yiir . A= Cross-5oct]in*alnrcflL- r stuck , fi. * Tm*** 1 Absolut e temperatur e a t standar dconditions- , 630° B . Pt n= Aiisohitnpressur e at standar dconditions , 29.03 Indie; * Ug . 6 . References. Murk . L . S „ Mechanica l Engineers ' Hum i book , McOraw-HII l Boo k Co. , Inc. , Ne w York " N Y , 1951 . Perry . J . H. . Chemica l Engineers ' Han d book , McGraw-Hil l Boo k Co. , Inc. , Ne w Ynrtr " N.Y. . I0GO . ' Sliigchara . R . T. , W . F . Todd , an dw s Smith . Significanc e o f Error s i nStac k

Sam- . plln g Measurements . Pape r presente dn t

th e Annua l Meetin g o f

th e Ai r

Pollutio nContro l Association , St . Louis . Mo. . Jun e 14-19 , ifli o Standar dMetho dfo r Samplin g Stack s fo r Particulat e Matter . In : 197 1 Boo k o f AST M Standards , Par t

23 , Philadelphia , p a197 1 AST M Designatio nD-2D2B-71 . Vcnuard . J . K. . Elementar y Flui dMechan
Irs . Joh nWile y & Sons . Inc. , Ne w Yor k NY " 1947 . ' -

PIP E COUPLIN G TUBIN G ADAPTE R

Figur e 2-1 . Pito t

tube-manomete

r assembly . 

### B- 4P.3 8

PLAN T DATE , RU N NO . STAC KDIAMETER , in . BAROMETRI C PRESSURE , in . Hg . STATI C PRESSUR E I N STAC K{P g ) , in . Hg . OPERATOR S SCHEMATI C O F STAC K CROS S SECTIO N

Travers e poin t numbe r Velocit yhead ,

in . H 2 0

AVERAGE : 

## v£ 7

' Slac k Temperatur e rts>.°f

Figur e 2-2 . Veiocll ytravers e dala .

B- 5P.3 9

MIT T HO O 3—CA S ANALYSI S TORCARSO N DIOIIDI , EXCES S Ala , AN O DB T MOLECTTLA * WKICH T 1 . Principl e and

applicability. 1. 1 Principle . A nIntegrate do r gra b ga s sampl e I s extracte dfro masamplin g poin t an danalyze dfo r

It s component s usin g a n Orsa t analyzer . 1. 2 Applicability . Thi s metho dshoul db e applie donl y whe nspecifie db y th e tes t pro cedure s fo r

determinin g complianc e wit htb e Ne w Sourc e Performanc e Standards . Th e tes t procedur e wil l Indicat e whethe r agra b sam pl e o r a nIntegrate dsampl e I s t o b e used . 2 . Apparatus. 2. 1 Gra b sampl e (Figur e 3-1) . 2.1. 1 Probe—Stainles s stee l o r Pyrex 1 glass , equippe dwit hafilter t o remov e partic
ulat e matter . 2.1. 2 Pump—One-wa y Bqueez e bulb , o r equivalent , t o transpor t ga s sampl e t o analyzer . »Trad e name . 3. 2 integrated sample {Figure i-2). 3.2. 1 Probe—Stainles s stee l o r Pyrex 1 glass , equippe dwit b * Alte r t o remov e par ticulat e matter . 2. 2 JAir-coole dcondense r o r equivalent — T o remov e an y exces s moisture . 3.2. 3 Needl e valve—T o adjus t flow rate . 2.2. 4 Pump—Leak-free , diaphrag mtype , o r equivalent , t o pul l gas . 2.2. 5 Rat e meter—T o measur e aflow rang e fro m0 t o 0.03 5 cfm . 3.2. aFlexibl e bag—Tedlar, 1 o r equivalent , wit hacapacit y of

2 t o 3 cu . ft . Lea k

tes t th e ba g l nth e laborator y befor e using . 2.2. 7 Pito t

tube—Typ e S , o r

equivalent , attache dt o th e prob e B O tha t th e samplin g flo w rat e ca nb e regulate dproportiona l t o th e stac k

ga s velocit y whe nvelocit y I s vary in g wit htim e o r

asampl atravers e L a conducted . 2. 3 Analgia . 3.3. 1 Orsa t

analyzer , o r

equivalent .

PR08 E PR ' FLEXIBL E TUBIN G T O ANALYZE R / FILTE R (GLASS NOOl )

SQUEEZE BULB
Figur e 3-1 . Grab-samplin g train . RATE METE

R VALV E AIR-COOLE D CONDENSE R PROS E

FILTE R [GLAS S WOOL} QUIC K DISCONNEC T

A RIGI D CONTAINER ^ Figur e3-2 * Integrate d ga s • sampUngtrain . 3 . Procedure . 3. 1 Gra b sampling . 3.1. 1 Se t

u p th e equipmen t

a s show nI n Figur e 3-1 , makin g sur e al l connection s ar e leak-free . Plac e th e prob e I nth e stac k a t a samplin g poin t

an dpurg e th e samplin g line . 3.1. 2 Dra w sampl e int o th e analyzer . 3. 2 Integrate dsampling . 3.2. 1 Evacuat e th e flexible bag . Se t u p th e equipmen t

tmshow ni nFigur e 3- 2 wit hth e ba g disconnected . Plac e th e prob e I nth e stac k an dpurg e th e samplin g line . Connec t th e bag , makin g sur e tha t al l connection s ar e tigh t an dtha t

ther e ar e n o leaks . 3.2. 3 Sampl e a t

arat e proportiona l t o th e stac k velocity . 3. 3 Analysis . 3.3. 1 Determin e th e CO. , O, . an dC O con centration s a s soo n« apossible . Mak e a s man y passe s a s ar e necessar y t o giv e constan t read
ings , i f mor e tha nte np&me s ar e necessary , replac e th e absorbin g solution . 3.3. 2 Fo r

gra b sampling , repea t th e sam plin g an danalysi s unti l thre e consecutiv e sample s var y n o mor e tha n0. 5 percen t b y volum e to r

eac hcomponen t

bein g analyzed . 3.3. 3 Fo r

Integrate dsampling , repea t th e analysi s o f

tiv e sampl e unti l thre e consecu tiv e analyse s var y n o mor e tha n0. 2 percen t b y volum e fo r

eac hcomponen t

bein g analyzed . 4 . Calculations. 4. 1 Cartw ndioxide . Averag e th e thre e con secutiv e run s an drepor t th e resul t

t o th e neares t 0.1 % CO r 4. 2 Exces s air . Us e Equatio n3- 1 t o calcu
lat e exce-s s air . an daverag e th e runs . Repor t th e resul t

t o th e neares t

0. 1 % exoee s air . * %U A = (%Oi)-0.S(%CO ) „ lft n 0.2G4(% N,)-( % O.)+0.5( % C0) AiU U equatio n3- 1 •where : %EA= Percen t

exces s air . % 0 , = Percen t

oxyge nb y volume , dr y basis . %N J -=Percen t

nitroge nb y volume , dr y basis . %CO=-Percen t

carbo nmonoxid e b y vol
ume , dr y basis . 0.2*4- = Rati o o f

oxyge nt o nitroge nl nai r b y volume . 4. 3 Dr y molecula r

weight . Us e Equatio n 3- 2 t o calculat e dr y molecula r weigh t an d averag e th e runs . Repor t th e resul t

t o th e neares t tenth . M * = 0.44(%CO,)-f0.32{%0 3 ) + 0.28(%N, + %CO ) equatio n3- 2 where : Ma=Dr y molecula r

weight , lb./lb-mole . %CO*-=Percen t

carbo ndioxid e b y volume , dr y basis . "iOfspercen t

oxyge nb y volume , dr y basis . %N-j=Percen t

nitroge nb y volume , dr y basts . 0.44=Molecula x weigh t o f carbo ndioxid e divide db y ioo . 0.32=Molecula r

weigh t o f oxyge ndivide d b y 100 . 0.28=Molecula r

weigh t of nitroge nan d C O divide db y 10O . fl. Rt ferences. Altahuller , A . P. . e t

al. . Storag e of

Oase s an dVapo nI nPlasti c Bags . Int . J . Air & Wate r Pollution . 6:75-81 , 1983 . Conner . Willia mD. . an dJ . 8 . Nader , Ai r Samplin g wit hPlasti o Bags , Journa l of th a America nIndustria l Hygien e Association , 25:291-297 , May-Jun e 1964 . Devorkin , Howard , e t al. . Ai r

Pollutio n Sourc e Testin g Manual , Ai r Pollutio nCon
tro l District , Lo aAngeles , Calif. , Novembe r 1993 . ii B- 6P.4 Q

METHO D 5—DETERMINATIO No r PAR Iicn.AT E EMISSION S Fnoi nSTATIONAR YSOURCE S 1 . Princip e and

aiiphcnhility. 1 1 Principle . Particulat e matte r i. s with
draw nlsoklnctlcall y fro mth e sonrr e an dil s weigh t i s determine dgr.ivtnietrlcnll y afte r re mova l o f uncombine dwater . 1. 2 Applicability . Thi s ni^tlio dI s ayiplir.i
Ui e lo r th e determinatio nn i pnrtlculal e emis
sion s fm mstationar y source s onl y whe n specifie db y th e tes t

procedure s fo r

determin
in g complianc e wit hNew Sourc e Perform
anc e Siandards . 2 . Apparatus. 2 I Samplin g train . Th e desig n-specifica
tion s of th e paniculat e samplin g trai nice d b y EPA(Figur e 5-1 ) ar c describe dI nAPH)
- 0581 . Commercia l model s o l thi s trai nar e available . 2.1. 1 Noz?.le—Stainles s stee l (31G) wit h sharp , tapere dleadin g cfic . 2 1. 2 Probe—Pyrex 1 glas s wit hahealin g syste mcapabl e o r

maintainin g aminimu m ga s temperatur e of

250 " F . a t

th e extt . en d durin g samplin g t o preven t condensatio n fp'i noccurring . Whe nlengt hllmltal-hm s (greate r tha nabou t

8 ft. ) ar e encountere da t temperature s Ic-'- s tha nGOO" " F. . Incolo y (12.

I' , o r equivalent , ma y b e used . Probe s fo r sam plin g gas'stream s a l temperature s l nexces s of 600 " F . mus t

hav e bee napprove db y th e Administrator.
- 2.1 3 Pito t

tube—Typ e S . o r

equivalent , attache dl o prob e t o monito r stac k ga s velocllv . 2.1. 4 Fille r

Holder—Pyrex ' glas s wit h he-alln g syste mcapabl e of maintainin g mini
mu mtemiwraLure o f

225 " F . 2.1. 5 Impinger a/

Condenser—Fou r

impin
ger s connecte dl nfierics wit hgla& s bal l Join t llttlngs . Th e first, third , an dfourt himpin
ger s or e of

th e Gree nburg-Smit hdesign , modifie db y replacin g th e ti p wit ha'/-.-Inc h I D glas s tub e extendin g t o one-hal f Inc h fro mth e botto mof

th e flask . Th e secon dim
pinge r l s o r th e Greenburg-Smit hdesig n wit htli e standar dtip . Acondense r ma y b e use dt nplac e of

th e Impinger s provide dtha t th e moistur e conten t of th e stac k

ga s ca n stil l h e determined . 2.1. 6 Meterin g system—Vacuu mg;iugc , leak-fre e pump , thermometer s capabl e of measurin g temperatur e L o withi n5 * F. , dr y ga s mete r

wit h2%accuracy , fin drelate d equipment , o r

equivalent , a s require dt o mainUilt i a nIr-o

k lueti c samplin g rat e nn dt o determin e sampl e volume . 2.1. 7 Barometer—T o measur e atmospheri c pressur e t o -£0. 1 Inche s Hg . 2. 2 Sampl e recovery . 2 2. 1 Prob e brush—A t leas t a s lon g a s probo . 2.2. 2 Glm

w was hbottles—Two . 2.2. 3 Glas s sampl e storag e containers . 2 2. 4 Graduate dcylinder—25 0 ml . 2. 1 Analysis . 2. 3 1 Ola.-. s weighin g dishes . 2.3. 2 Deslce.ilor . 2.1. 3 Analytica l balance—T o measur e t o ±0. 1 mg . 2. 1 1 Tri p balance—30 0 g . capacity , t o tnennur e l o -+-0.0

5 g . 3 Rcartrnts. 3. 1 Sampling . 3.1. 1 Fillers—Glas s fiber . MS A110 0 HH' . o r equivalent , numbere dfo r Identificatio n an dpr e weighed . 3.1. 2 Silic aget—TiHlicatln g type . 0-1 0 mesh , drie da t

176 * C . (350 * F. ) fo r 2 hours . 3.1. 3 Water . 3.1. 4 Crushe dIce . 3. 2 Sampl e recovery . • * 2. 1 Acetone—Reagen t grade . 3. 3 Analysis . 3.3. 1 Water . IMPINGE R TRAI N OPTIONAL . HA YB E REPLACE D B YA N EQUIVALEN TCONDENSE R HEATE D ARE AFILIE R HOLDE R / THERMOMETE R CHEC K PROB E

REVERSE-TYP E PITO TTUB E 

# V

X

PIT0 1 MANOMETE R

ORIFIC E IMPINGER S IC E BAT H BY-PAS S VALV E 

# 31

THERMOMETER S VALV E
„VACUU M LIN E

\ VACUU M \ GAUG E MAI N VALV E 7 ' /• " OR * TES TMETE

RAIR-TIGH T

PUM P Figur e 5-1 . Paniculate-samplin g bain . 3.3. 2 Dcslrxnn l -Dricrtte. ' Indicating . 4 . Procedure. 4. 1 .Samplin g 4.1. 1 Afte r

se l ed.In* ; (h e samplin g sit e an d th o minimu mnumbe r o f samplin g point-; , determin e th e stac k

pressure , temperature , moisture , an drang e o f velocit y head . 4. 1 2 Preparatio no f collectio ntrain . Weig ht o th e neares t

grn mapproximatel y 20 0 g . of silic agel . Labe l afilter of prope r diam
eter . desiccate 1 fo r

a t leas t 2 4 hour s an d weig ht o th e neares t

0. 5 mg . I naroo mwher e tli c relativ e humidit y t s les s tha n50' ; . Plac e 10 0 ml . of

wate r I neac ho

f th e first

iw o Impingers , leav e th e thir dImpinge r empty , am i plac e approximatel y 20 0 g . of prcweiglie d sltlr age l I nth e fourt himpinger . H e I . u p th e trai nwithou t

th e proti c a s InFigur e 5-1 . Lea k chec k th e snmpliui : trai na t tli e .'.:im
plln g sil aliy pluggin g u p tli e Inle t t o 1 li e fil
te r ivildu r nn dpul l hit : a1 5 in . Hg vacuum . A lenkag e rat e no t

I nexces s of

0.0 2 c.f.ni . a t

a vacuu m<;

f 1 5 In . H g i s acceptable . Attac h th e prob e an dadjus t

th e heate r

t o provide ; n ga s temperatur e o'

f abou t 250 ° F . a t

th e prob e outlet . Tur no nth e filte r heatin g system . Plat e crushe dIc e aroun dth e Impingers . Ad d mor e te c durin g th e ru nt o • ee p th e temper atur e o r !h " gase s leavin g th e las t Impinge r a s u»v. - a s possibl e an dpreferabl y a t 70 " F . o r ie.*-s . Temperature s abov e 70 ° P . ma y result , i ndamag e t o th e dr y [jn s mete r fro meithe r moistur e condensatio no r excessiv e heat . 4.1. 3 Particulat e trai noperation . Fo r eac h run , recor dth e dat arequire do nth e exampl e si i le t show nI nFigur e S-2 . Tnk c reading.- ; ;i t cae.ii samplin g point , n l leas t every 5 minutes , nu dwhe nsignifican t

change s I nstac k

con dition s necessitat e additiona l ndjustnieut s I nflow mie . T o begi nsampling , positio nWin w>zr\" n t th e firs t

travers e pnhi l wit hth e ti p puintin g directl y Int o th e ga s stream , lrnnirdintcl y star t

tli e pum p an dadjus t u- e Ilo w t o Isokineti c conditions . Sampl e fo r n> , l^as t f j minute s a t

e;te htravers e point : sani
plhi Rlinn : mus t

ti c th e sam e tor

eac hp:ilm . Mnhilnl nIsokineti c samplin g IItrnught-u l HI P samplin g period . Nomograph s ar e nvnilM-l c whic hnic

l i nth e rapi dadjustment , o f th e samplin g rat e withou t othe r eompulnlluns . AP'l'l ) 057 0 detail s th e procedur e for usln»
- thes e tioinngrnphs . Tur nof f tli e pum p a t

tb e conclusio no r

eac hru nnu drecor dth e fina l readings . Remov e th e prob e an dnozzl e Ir.- m th e slac k

nn dhandl e Inaccordanc e wit hth e sampl e recover y proces s describe dI nsectio n 4.2 . 4. 2 Sampl e recovery . Exercis e car e l nmov in g th e collectio ntrai nTro mth e tes t sit e t o th e sampl e recover y are at o minimiz e th e los s o f collecte dsampl e o r th e gai nof extraneou s particulat e matter . Se t asid e a portio no f

th e aceton e use dl nth e sampl e recover y a s ablan k

fo r analysis . Measur e th e volum e of

wate r fro mth e first

thre e Im
pingers , the ndiscard . Plac e th e sample s I n container s a s follows : Container

No. 1. Remov e th e filter fro m It s holder , plac e i nthi s container , an dseal . Containe r

No. 2. Plac e loos e particulat e matte r an daceton e washing s fro mal l sample-expose dsurface s prio r t o th e Alte r I nthi s containe r

an dseal . Us e arazo r blade , brush , o r

rubbe r policema nt o los e adherin g particles . Container

No. 3. Transfe r

th e silic age l fro mth e fo\irt hImpinge r t o th e origina l con taine r an dseal . Us e arubbe r policema na s a nai dl nremovin g silic age l fro mth e Impinger . 4. 3 Analysis . Recor dth e dat arequire do n th e exampl e shee t

show nl nFigur e 6-3 . Handl e eac hsampl e containe r a s follows : Container

No. 1. Transfe r

th e filter

an d an y loos e particulat e matte r fro mth e sampl e containe r

to- atare dglas s weighin g dish , desiccate , an ddr y t o aconstan t weight . Re
por t result s t o th e neares t 0. 5 mg , Container

No. 2. Transfe r

th e aceton e washing s t o atare dbeake r an devaporat e t o drynes s a t

ambien t

temperatur e an dpres sure . Desiccat e an ddr y t o aconstan t weight . Repor t result s t o th e neares t 0. 5 mg . Containe r

No. 3. Weig hth e spen t silic age l an drepor t

t o th e neares t

gram . 5 . Calibration . Us e method s an dequipmen t whic hhav e bee napprove db y th e Administrato r t o calibrat e th e orific e meter , pito t tube , dr y ga s meter , an dprob e heater . Recalibrat e afte r eac htes t

series . 0 . Calculations. 0. 1 Averag e dr y ga s mete r temperatur e an daverag e orific e pressur e drop . Se e dat a shee t (Figur e 5-2] , 1 Trad e name . 1 Trad e name . •Dr y usin g Drlerlt e la t 70 ' P.±10 * F . B-r7P.4 1

6. 3 Dr y ga s volume . Correc t th e sampl e volum e measure db y th e dr y ga s mete r t o standar dcondition s (70 s F. , 29.9 2 Inche s Hg ) b y usin g Equatio n5-1 . 

### * m

### „ d

### *»\ T i 

### j v Pitd

### / 

## ("• " A>- equatio n5- 1 where : V-n. . Volum e o r

ga s sampl e throug hth e dr y ga s mete r

(standar dcondi
tions) , cu . ft . V„ , = Volum e o f

ga s sampl e throug hth e dr y ga s mete r

(m e te r

condi
tions ) . cu . ft . T,,,, " Absolut e temperatur e a t standar d conditions . 630 * R . T_- " Averag e dr y ga s mete r temperature , ' R . P bir « . Barometri c pressur e a t th e orific e meter , Inche s Hg . A H = Averag e pressur e dro p acros s th e orific e meter , Inche s H.,0 . 13. 6 = Specifl c gravit y o f mercury . P,,. = Absolut e pressur e a t standar dcon - ditions . 29.9 2 inche s Hg . 6. 3 Volum e °t

wate r vapor . : pB.O RT. * lb . Y 

### -.-- v 

### «-5r=-T : B , O P.t d45 4 gm .

•=0.0474^^* .

m l . - 3 equatio n5- 2 where : Vw ,j = Volum e o f

wate r vapo r i n th e ga s sampl e (standar dconditions) , cu . ft . Vt,< = Tota l volum e o f liqui dcollecte dI n Impinger s an dsilic age l (se e Fig
- u r e 6-3) , ml . p» 1 n= Densit y o f

water . 1 g./ml . M»,o = Molecula r

weigh t

o f water , l alb. / lb.-mole . R-=Idea l ga s constant . 21.8 3 Inche s Hg—cu . ft./lb.-mole-'B . T., d = Absolut e temperatur e ftt standar d conditions , 530 * R . P l U = Absolut e pressur e a t standar dcon - ditions , 29.9 2 Inche s Hg . 6. 4 Moistur e content .

B.., = V-.. H equatio n5- 3 WIK*ID : lt. „ =]'rn|M)i i In

nl> y vuliiitioo l wa l PIvapo r I nth e ga s stream , ilinii-nKlonlei-s . v

- 1 „i=V<j]nni( ' o

f wate r I ntii e en s sampl e (si-iiul-ir- l coii<Jlllon.s),cu . ll . ^ ".- j =>Vi)lum

e o f (in s sampl e tliroiiRhtb o dr y po s mi'l w (stnnilar dconditions) , cn . ft . 6. 5 Tota l particulat e weight . Determin e t h e tota l particulat e catc hfro mth e su mo r t h e weight s o n th e analysi s dat ashee t (Figur e 5-3) . 0. 6 Concentration . 6.6. 1 Concentratio nI ngr./s.c.f . 

# •'•-( ao,54 

# £-.)0fc ) equatio n5- 4 wliero : c' . = ConcfntnilIo no

f parLirnlut e matte r

In sln<k cas , gr./s.cf,
- dr y basis . M,-=Toln l amoun t

o f particulat e raatler

colle drd , IHR . *".id=Volum no

f ca s sampl e llirouet i dr y ga s nicto r (standar dconditions) , cu . ft . m m M lOCMIOH . at«»io» _ out WHNO . SAU» U |0 1 K(\_ Will i 1(11*0 . •lllltH, . **-ni»-iiiPt"fu*f _ |UOUUuCMfUUK _ A»UW D no i num . * _ mMfiwtsiTiw o ftm UNCTM . K WIHIW»J*tI*,t». _ nOUHIMiaStlTIW . r. "icr o

I u v i i^ t roiNi Muvs a

lOri L j*mi*« )

t «

kVtfACt j un e Mft«u* t (f,l . ta. H- | scHcin e wsi->c " «o » veno *

tivtunr c Uli . *f vtioc m

m* o OlfKUNTIA l

ACW K oiuic l Wil l .'III. In . IIj O IV- I n * GAtsiun t nupiMnw i A l 0* 1 C«SUITf " n a n ""•in.'-* '

.., . OU I I K

II« eB1 l.* |

t.e.

»--« • u w (era TIWUTUM . *• < lEVftllllW I

ll*TM ; c«D[-ru < o

n uu i •'•u i

Fig, - 4.6. 3 Concentratio nI nlb./cu . ft .



## UiooowK_

2>20f i

## , M. . equatio n5- 5 where : c.=*

> Concentratio no

f pinllonb l nma l II TI

nslac k Kofl , Ib./s.c.l. , dr y biwis . 4S3,ii00-=M(;/lb . M B = Tota l amoun t

o f pai lldilnl e matte r

e o 1 1 acted , inc . V.„ Hd -Volum e o

f Ra. " sampl o throug hdr y ga s mMo " (standar dcomllltona) , cu . ft . 6. 7 Isokineti c variation . I-T . •.[(2 :

002C7 in . Hg-cu . ft . ml-° R 

### )v,.+^(p.. +r 

### |)](.. .

eV.P.A „ equatio n5- 6 VI I' l i I- l'>'iiiii t

n ( ls.ikl'11'iic siMtipliTir . V lp -='i'ul;i l vi.IIIIII II' l lli-uii l MMOI'IIM] I nlni|i|in:-i s 'anrl !UII<-;

i i- d(!-*.•• « Tic . fi--)) . ml . .(Hi,r."-|trnsll y o

f vat'T , 1 R./mt . I t = I'l*-:*, ! c:i*

= CfiilftiHil. , 2 1 > n Ini-li M llfi-cil . fl./llt . i.;»|.-°H . Miigo-M'-lKiiln r

w.-lirh l o f uritrr , 1.1 Ih./lli.-mol-* . V n -Vtiliitiirti(p:)s'iiiii]i|i ' tlilnilL-lilhr.drj-pa.' ! irid* T (111- I••' • em u Iiii'HIS) , rn . (I . TB . = Ali-i-ilut

c flvfuic' dr y g:» mete r tuii-piT-ilnn ; («IM . l-lpntr d •.').• • It . I'i.,i * lliiruiiii-iii c ]ir<'5-.iin
- n l suii|-l|ii| ! Site , Irit-h^.-
- II.- . All--Avmi'i- c |in--i«iiir

> ilin p nrrus s th o orllii o (*•• « Mi.' , ft J) . Iiifhi- s Hi" . T.-nAliSirlnl. e iiTi'isii:i

> stiti- k £n 3 Innporntur o (i"* " I-'IK. f > 21,"It . fl—Tobii siuiiplini ! tltiH* . min . V.*»Sliick

p:i s vrlin-ii y <*;ili:iil*i,|.*i l b y M-llin- l 2. I*:i|ii'ili.in'

J2. f t friT. I',
- AiiSiilulcsliirl i (j;i * ] 1 1 rssurn , lnrli<*f

l lip . ' An-'Cinfs-.ci-fllnn-i l or en n f rinzrle , ri\. ft . fi.8 Acceptabl e results . Th e follow ! n c rniif- c set s tli e limi t o n acceptabl e Isokineti c samplin g results ; L f 00^. < I < 110% . th e result s ar e scccpUiblc , otherwise , rejec t

th o result s an drepca L t h o lest . 7 . llr/.-rrjirr.. Addendu mt o Specification s fo r Incinerato r Tesiin p ftt

Federa l Facilities . PHS , NCAPC . Dec . fi. lfiC7 . Martin . Rober t

M. . Constructio nDctnJl s o f Jr.r-1-.inrtl c Sourc e Samplin g Equipment . Kti
vironmcntn l Protectio nAgency . APTD-05FH . Rom . Jerom e J. . Maintenance . Calibration , a n dOperatio nol Isokineti c Sourc e Sam
plin g Fqulpment . Environmenta l Protectio n ARCUCV . APTD-057C . Smith , W . S „ R. T . ShlRchnra . nn dW . P . Todd . A Metho do f Interpretin g Stac k Sam
plin g D;iU\ . Pape r

presente da t

th e 63 dAn
nua l Meetin g o f

th e Ai r

Pollutio nContro l A:i;;oc-latlon . St . Louis . Mo. . Jun e 14-19 , 1970 . Smith . W . S. . e t

a l . Slac k

Ca s Samplin g Improve dnn dSimplifie dwit hNe w Equip
- ment . AI'C Apape r No . 67-119 , 1067 . Specification s fo r

Incinerato r

Testin g a t Federa l Facilities , PHS . NCAPC , 1967 .

B - 8P.4 2

PLANT , DAT E RU N N0. _

CONTAINE R NUMBE R 1 2 TOTA L WEIGH TO F PARTICULAT E COLLECTED , m g FINA LWEIGH T TAR E WEIGH T WEIGH TGAI N

FINA L INITIA L LIOUI D COLLECTE D TOTA LVOLUM E COLLECTE D VOLUM E O F LIOUI D WATE R COLLECTE D IMPINGE R VOLUME , m l SILIC AGE L

WEIGHT , fl

9 " m l CONVER TWEIGH TO F WATE R TO VOLUM E B YDIVIDIN G TOTA LWEIGH T INCREAS E B

YDENSIT

YO F WATER . ( 1 g . nil) :

INCREAS E 9 = VOLUM E WATER , m l 1 1 g/mt ) Figure5-3 . Analytica l data .

B- 9P.4 3

•MFTKO H 0 VISTTA LDETE RMITTATIO NOf TH E OPACTT TO FEMISSION S FBO M STATIONAB T SOURCE S > n Man y stationar y source s discharg e visibl e emission s Int o th aatmosphere : thes e emis
sion s ar e usuall y l ntb e shap e o f s plume . ThJ ametho dInvolve s th e determinatio no f plum e opacit y b y qualiae dobservers . Th e metho dInclude s procedure s fo r th atrainin g an dcertificatio no f

observers , an dprocedure s t o b e use di ntb e fieldfo r determinatio no f plum dopacity . Th o appearanc e o f aplum e a s viewe db y a nobserve r depend s upo nanum be r o f variables , som e o f

whic hma y b e con trollabl e an daom e o f whic hma y no t

b e controllabl e l nth e field. Variable s whic hca n b e controlle dt o a nexten t t o whic hthey , n o longe r exer t asignifican t

Influenc e upo n plum e appearanc e Include : Angl e o f th e ob
serve r wit hrespec t

t o tb e plume : angl e o f th e observe r wit hrespec t

t o th o sun ; poin t

o f observatio no f

attache dan ddetache dstea m plume ; an dangl e o f

th e observe r

wit hre spec t t o aplum e emitte dfro marectangula r stac k wit halarg o lengt ht o widt hratio . Th e metho dInclude s specifi c criteri aapplicabl e t o thes e variables . Othe r variable s whic hma y no t b o control
labl e I nth e fieldar e luminescenc e an dcolo r contras t betwee nth e plum e an dth e hack
groun dagains t

whic hth e plum e I s viewed . Thes e variable s exer t

a ntniluenc o upo ntb e appearance-o f

aplum e o aviewe db y a nob
server . and 1 ca naffec t

th e abilit y o f

th e ob
serve r t o accuratel y assig nopacit y value s t o th e observe dplume . Studie s of th e theor y o f plum o opacit y an dfieldstudie s hav e dem
onstrate dtha t

aplum e l amos t

viaibl e an d present s th e greates t

apparen t

opacit y whe n viewe dagains t

acontrastin g background . I t follow s fro mthis , an dlaconfirme db y field trials , tha t

th o opacit y o f

aplume , viewe d undr r condition s wher e acontrastin g back
groun dL

s presen t ca nb e assigne dwit hth e greates t degre e o f

accuracy . However , tb e po tentia l fo r

apositiv e erro r

l s als o th e greates t whe naplum e l s viewe dunde r suc hcontrast in g conditions . Onde r condition s pretestin g al«s acontrastin g background , th e apparen t opacit y o f

aplum e l s les s an dapproache s zer o a s th e colo r

an dluminescenc e contras t decreas e towar dzero . A s aresult , significan t negativ e bia s an dnegativ e error s ca nb o mad e whe naplum e is viewe dundt r Imm contrastin g conditions . Anegativ e bia s de
crease s rathe r

tha nIncrease s th e possibilit y tha t aplan t operato r

wil l b e cite dfo r

avio
latio no f opacit y standard s dn e t o observe r error . Studie s hav e bee nundertake nt o determin e th e magnitud e o f

positiv e error s whic hca n b e mad e b y qualifie dobserver s whil e read
in g plume s unde r

contrastin g condition s an d usin g th e procedure s se t fort hl nthi s method . Th e result s of thes e studie s (Hel d trials ) whic hInvolv e atota l of 76 9 set s o

f 2 5 reading s eac har e a s follows : (1 ) Fo r blac k plume s (13 3 set s a t

asmok e generator) , 10 0 percen t o f th e set s wer e ren dwit hapositiv e erro r - o f lea i tha n7. 5 percen t opacity : 9 3 percen t

wer e rea dwit h apositiv e erro r

of les s tha n5 percen t

opacity . (3 ) Fo r whit e plume s (17 0 set s a t asmok e generator . 16 8 set s a t

acoal-fire dpowe r

plant , 20 3 set s a t

asulfuri c aci dplant) , 9 9 percen t o f th e set awer e rea dwit hapositiv e erro r o f les s tha n7. 5 percen t

opacity ; 8 5 percen t

wer e rea dwit hapositiv e erro r ones s tha n5 per cen t opacity . Th e positiv e observationa l erro r ar^o-late d •wit ho naverag e o f

twenty-flv e reading s i s therefor e established . Th e accurac y of
- th e metho dmus t

b e take nint o account-whe n determinin g possibl e violation s o f appli
cabl e opacit y standards, . T o r » set , positiv e error=averag e opacit y determine db y observers ' 3 6 observations
averag e opacit y determine dfro mtransmls
someter' s 2 5 recordings . 2 . Principle and applicability. 1. 1 Principle . Th e opacit y o f emission s fro mstationar y source s l adetermine dvis
uall y b y aqualifie dobserver . - 1. 2 Applicability . Thi s metho dI s appli
cabl e fo r

th e determinatio no f th e opacit y of emission s fro mstationar y source s pur suan t t o 160.11(b ) an dfo r qualifyin g ob
server s fo r

visuall y determinin g opacit y o f emissions . 2 . Procedures . Th e observe r qualifie dl n accordanc e wit hparagrap h8 o f thi s metho d shal l us © th e followin g procedure s fo r vis
uall y determinin g th e opacit y o f emissions : 2. 1 position.-Th s qualifie dobserve r shal l stan da t adistanc e sufficien t t o provid e a clea r vie w o f

th e emission s wit hth e su n oriente dl nth e 140 * secto r t o hi s back . Con
sisten t with-maintainin g th e abov e require
ment , tb e observe r

shall , a s muc ha s possible , mak e hi s observation s fro mapositio nsuc h tha t hi s lin e o f

visio nl s approximatel y perpendicula r

to th e plum e direction , an d whe nobservin g opacit y o f emission s fro m rectangula r

outlet s (e.g . roo f

monitors , ope n baghouses , noncircula r stacks) , approxi
matel y perpendicula r

t o tb e longe r

axi s o f th e outlet . Tb e observer' s lin e o r sigh t shoul d no t includ e mor o tha non e plum o a t atim e whe nmultipl e stack s ar e Involved , an dI n an y cas e tb e observe r shoul dmak e hi s ob
servation s wit hhi s lin e o f sigh t perpendicu
la r t o th e longe r

axi s o f suc hase t

o f multi
pl e stack s (e.g . stu b stack s o nbaghouses) . 2. 2 Fiel drecords . Th e observe r Bhal l re cor dtb e nam e o f

th e plant , emissio nloca
tion , typ e facility , observer' s .nam e an d affiliation , an dth e dat e o nafielddat ashee t (Figur e 9-1) . Th e time , estimate ddistanc e t o th e emissio nlocation , approximat e win d direction , estimate dwin dspeed , descriptio n ot th e sk y conditio n(presenc e an dcolo r o r clouds) , an dplum e backgroun dar arecorde d o nafielddat ashee t

a t th e tim e opacit y read
ing s ar e Initiate dan dcompleted . 2. 3 Observations . Opacit y observation s shal l b e mad e a t

th e poin t

o f greates t

opacit y i ntha t portio no f

th e plum e -where con dense dwate r

vapo r i s no t present . Th e ob
serve r shs Uno t

loo k continuousl y a t

th e plume , bu t

In*ten dshal l observ e tb o plum e momentaril y a t

15-sscon dintervals . 2.3. 1 Attache dstea mplumes . Whe ncon dense dwate r

vapo r l s presen t

withi nth e plum e B S I t

emerge s fro mth e emissio nout let , opacit y observation s shal l b e mad e be
yon dth e poin t

I nth e plum e a t

whic hcon dense dwate r

vapo r I s n o longe r

visible . Th e observe r shal l recor dtb e approximat e dis
tanc e fro mth e emissio noutle t t o th e poin t I nth e plum e a t

whic htb e observation s ar e made . 2.3 5 Detache dstea mplume . Whe nwate r vapo r l ntb e plum e condense s an dbecome s visibl e a t

adistinc t

distanc e fro mth e emis
sio noutlet , th e opacit y o f emission s shoul d b e evaluate da t

th e emissio noutle t

prio r t o th e condensatio no f

wate r vapo r an dtb e for
matio no f

th e stea mplume . 2. 4 Recordin g observations . Opacit y ob
servation s shal l b e recorde dt o th e neares t 5 percen t a t 15-secon dinterval s o na nob
servationa l recor dsheet . (Se e Figur e 9- 2 fo r a nexample. ) Aminimu mo f 2 4 observation s shal l b e recorded . Eac hmomentar y observa
tio nrecorde dshal l b o deeme dt o represen t th e averag e opacit y o f emission s fo r

aJp
Eecon dperiod . 2. 5 Dat aReduction . Opacit y shal l b e de
termine da s a naverag o o f 2 4 consecutiv e observation s recorde da t 15-eecon dintervals . Divid e tb e observation s recorde do nth e rec or dshee t

Int o set s o f

2 4 consecutiv e obser
vations . Ase t

I s compose do f

an y 2 4 con secutiv e observations . Set s nee dno t b e con secutiv e l ntim e and-I nn o cas e Bhal l tw o set s overlap . Fo r

eac hBet

o f 2 4 observations , calculat e tb e averag e b y summin g th e opacit y o f th e 2 4 observation s an ddividin g thi s Bum b y 24 . I f o napplicabl e standar dspecifie s a n averagin g tim e requirin g mor e tha n2 1 ob
servations , calculat e th e averag e fo r al l ob
servation s mad e durin g th e specifie dtim e period . Recor dth e averag e opacit y on arecor d sheet . (Se e Figur e 9- 1 fo r a nexample. ) 3 . Qualifications and

testing. 3. 1 Certificatio nrequirements . T o receiv e certificatio na s aqualifie dobserver , acan- - dldat e mus t

b o teste dan d.demonstrat e th e abiUt y t o assig nopacit y reading s l nfl percen t Increment s t o 2 5 differen t blac k plume s an d 2 9 differen t

whit e plumes , wit ha nerro r no t t o exceo d1 5 percen t

opacit y o nan y on e readin g an da naverag e erro r no t t o excee d 7. 5 percen t

opacit y i neac hcategory . Candi
date s ahal l b e teste daccordin g t o th e pro cedure s describe dI nparagrap h3.3 . Smok e generator s use dpursuan t t o paragrap h3. 2 shal l b e equippe dwit hasmok e mete r whic h meet s th o requirement s o f paragrap h3.3 . Th e certificatio nshal l b e vali dfo r aperio d o f Q months , a t

whic htim e th e qualificatio n procedur e mus t

b e repeate db y an y observe r t norde r t o retai ncertification . _r " 3. 2 Certificatio nprocedure . Th e certifica
tio ntee t consist s o f

showin g th e candidat e a complet e ru no f

6 0 plumes—2 6 blac k

plume s an d2 5 whit e plumes—generate db y asmok e generator . Plume s withi neac hse t o f 2 5 blac k an d2 5 whit e run s shal l b e presente dI nran do morder . Tb e candidat e assign s a nopacit y valu e t o eac hplum e an drecord s hi s obser
vatio no nasuitabl e form . A t th e completio n o f eac hru no f

6 0 readings , th e scor e o f th e candidat e l s determined . I f a. candidat e fall s t o qualify , th e complet e ru no f 5 0 reading s mus t b e repeate dI nan y retest . Th e emok e tes t ma y b e administere da s par t o f a smok e schoo l o r

trainin g program , an dma y b e pre cede db y trainin g o r

fami l la r

Izatio nrun s o f th e smok e generato r

durin g whic hcandidate s ar e show nblac k

an dwhit e plume s o f know n opacity .

- 3. 3 Gmok o generato r specifications . An y smok e generato r

use dfo r

th e purpose s o f paragrap h3. 2 shal l b e equippe dwit ht. smok e mete r Installe dt o measur e opacit y acros s th e diamete r

o f tb e smok e generato r stuck , Th e smok e mete r

outpu t shal l displa y ln
stac k opacit y base dupo napathlengt hequa l t o th e etac k

exi t diameter , o naful l 0 t o 10 0 percen t char t recorde r

scale . Th e smok e mete r optica l desig nan dperformanc e shal l mee t th e speci f

cation s show nI nTabl e &-1 . Th e smok e mete r

shal l b e calibrate da s pre scribe dI nparagrap h3.3. 1 prio r t o tb e con duc t o f eac hsmok e readin g test . A t th o completio no f

eac htest , th e ser o an dspa n drif t ahal l b e checke dan dI f th e drift

ex ceed s -n l percen t

opacity , th e conditio nshal l b e correote dprio.
- t o conductin g an y subse
quen t tea t runs . Th e smok e mete r shal l b a demanstrated . a t

Ui e tim e o f

Installation , t o mee t tb e specification s liste dI nTabl e 9-1 . Thi j demonstratio nshal l b o repeate dfol
lowin g an y subsequen t repai r o r replacemen t o f th e photocel l o r

associate delectroni c cir
cuitr y Includin g th e char t recorde r

o r outpu t meter , o r

e»er y 6 months , whicheve r occur s first. $731 Calibration . Tho emok e mete r i s calibrate dafte r

allowin g aminimu mo f 8 0 mlnute awarmu p b y alternatel y produdn g simulate dopacit y o f

0 percen t

an d100 per cent . Whe neOabl e respons e a t 0 percen t

o r 100 percen t

i s noted , th e smok s mete r I s ad
Juste dt o produc e a noutpu t o f 0 percen t

o c 100 percent , a s appropriate . Thi s calibratio n shal l b e repente dunti l stabl e 0 percen t an d 10 0 percen t

reading s art. produce dwithou t adjustment . Simulate d0 percen t an d10 0 percen t opacit y value s ma y b o produce db y alternatel y switchin g tb e po-wer t o tb e ligh t sourc e o nan dof

f whil e th e smok e generato r Uno t producin g smoke . B-1 0P.4 4

TAB U fr-1

—

EUOKE fcCFJTERDESIG NAN O PStrOBMANC ESPBCinCAT ION S Parameter : a . Ligh t sourc e b . Spectra l respons e o f photocell . c . Angl e o f

vie w d . Angl e o f

projec
tion . e . Calibratio nerror . f . Zer o an dspa n • drift . g. Respons e time — Specification Incoudemsen t

lam p operate da t

nomina l rate dvoltage . Ph o topi c (dayligh t spectra l respons e o f th e huma neye — referenc e 4.3) . 15 * maximu mtota l angle . 15 * maximu mtota l angle . •±3 % opacity , maxi
mum . ± 1 % opacity , 3 0 minutes . £ 5 seconds . 3.3, 2 Smok e mete r

evaluation . Th e 6mok e mete r desig nan dperformanc e ar e t o b e evaluate da s follows : 3.3.2. 1 Ligh t

source . Verif

y fro mmanu facturer' s dat aan dfro mvoltag e measure ment s mad e a t

th e lamp , a s Installed , tha t th e lam p i s operate dwithi n-±6 percen t o f th e nomina l rate dvoltage . 8.3.2. 2 Spectra l respons e o f photocell . Veril y fro mmanufacturer' s dat atha t Ui e photocel l ha s aphotopl c response ; I.e , tb e spectra l sensitivit y o f tb e cel l Bhal l closel y approximat e th e standar dspectral-luminos
it y curv e fo r

photopl c visio nwhic hI s refer
ence di n(b ) o r

Tabl e 0-1 . 3.3.2. 3 Angl e o f

view . Chec k

constructio n geoincct y t o ensur e tha t th e tota l an^'l e o f vie w of tb e smok e plume , a s ree nb y th e photocell , doe s no t

excee d16' . Tb e tota l angl e o f vie w ma y b e calculate dfrom : t—2 tan- 1 d/2L , wher e tf

= tota l angl e o f

view ; d= th e su mo f

th e photocel l diameter-f-th e diamete r o f th e limitin g aperture ; an d L= trj adistanc e fro mth e photocel l t o th e limitin g aperture . Tb e limitin g apertur e l s th e poin t

I nth e pat hbetwee ntb e photocel l an dth e smok e plum e wher e tb e angl e o f vie w l amos t

restricted . I nsmok e generato r •mok e meter * thi s I s normall y -a norific e plate . 3.3.2. 4 Angl e o f

projection . Chec k

con structio ngeometr y t o ensur e tha t tb e tota l angl e o f projectio no f

tb e lam p o nth e smok e plum e doe s no t excee d16* . Th e tota l angl e o f projectio nma y b e calculate dfrom : 6=2 tan- 1 d/2L , wher e B= tota l angl e of pro jection ; d = th e su mo f tb e lengt ho f

tb e lam p filament + tb e diamete r o f tb e limitin g aperture ; an dL = th e distanc e fro mtb e lam p t o th e limitin g aperture . 3.3.2. 5 Calibratio nerror . Usin g neutral
densit y filters o f

know nopacity , chec k th e erro r betwee nth e actua l respons e an dth e theoretica l linea r

respons e o f

th e smok e meter . Thi s chec k

l s accomplishe db y first calibratin g tb e smok e mete r accordin g t o 3.3. 1 an dthe nInserttn g aserie s o f thre e neutral-densit y filters o f nomina l opacit y o f 20 , 60 , an d7 6 percen t I nth e Gisok e mete r pathlength . Filter s callbarte dwithi n± 3 per cen t shal l b e used . Car e shoul db e take n whe nInsertin g th e Alter s t o preven t stra y ligh t fro maffectin g th e meter . Mak e atota l o f five nonconsecutlv e reading s fo r eac h filter. Th e maximu merro r o nan y on e read
in g shal l b o 3 percen t

opacity . 3.3.2. 8 Zer o an dspa ndrift . Determin e th e zer o an dspa ndrif t b y calibratin g an d operatin g th e smok e generato r l nanorma l manne r ove r a1-hou r

period . Tb e drift

i s measure db y checkin g th e zer o an dspa na t th e en do f

thi s period . 3.3.2. 7 Respons e time . Determin e th e re spons e tim e b y producn g th e serie s o f five simulate d0 percen t

an d10 0 percen t

opacit y value s an dobservin g tb e tim e require dt o reac hstabl e response . Opacit y value s o f 0 percen t an d100 percen t

ma y b e simulate d b y alternatel y switchin g tb e powe r t o th e ligh t sourc e o 2 an do nwhil e th e smok e generato r

I s no t operating . 4 . F.efcrcnccs. 4. 1 Ai r Pollutio nContro l Distric t Rult a an dRtgulations , Lo s Angele s Count y Ai r Pollutio nContro l District , Regulatio nIV , Prohibitions , Rul e CO

. 4.2 Wslsburd , Melvi nL , Fiel dOperation s an dEnforcemen t

Manua l fo r

Air , TTJ3 . Envi
ronmenta l Protectio nAgency , Researc hTri
angl e Park , N.C , APTD-1100 , Augus t 1972 . pp . 4.1- 4 J6 . 4. 3 Condon , E . TJ. , an dOdisbaw , H. , Hand
boo t o f Physics , McGraw-Hil l Co. , N.Y „ N.Y . 1968 , Tabl e 3.1 , p . fr-82.

B-1 1FIGUR E 9- 1 - . . • v RECOR DO F VISUAL DETERMINATION O F OPACIT Y" 

### PAG E o f COMPANY LOCATION TES T NUMBER , DAT E TYP E FACIL1TY _ CONTRO L DEVIC E HOUR S O F OBSERVATION . OBSERVE R OBSERVE RCERTIFICATION DATE _ OBSERVE RAFFILIATION POIN T O F EMISSION S HEIGH T O F DISCHARG E POIN T

i H i\ » CLOC KTIM E OBSERVE RLOCATION Distanc e t o Discharg e Directio nfro

m Discharg e Heigh t o f Observatio nPoin t BACKGROUNDDESCRIPTION WEATHERCONDITION S HindDirectio n MindSpee d Ambien t Temperatur e SK YCONDITION S (clear , overcast . % clouds , etc. ) PLUME DESCRIPTION Colo r Distanc e Visibl e OTHE RINFOOttlO H Initia l

* Fina l SUMMARYO F AVERAG E OPACIT Y

Se t Numbe r

; Tlm f

Start—En d Opac1t \ •. Su m Averag e

Reading s range dfro

m 

### t o % opacit y Th e sourc e was/wa s no t I ncomplianc e wit h th e time evaluatio nwa s made . 

### .a t

O lFIGUR E 9- 2 OBSERVATION RECOR D PAG E O F COMPAN Y LOCATIO N TES T NUMBER " DAT E OBSERVER TYP E FACILIT Y~ POIN TO F EMISSIO N

C d I Hr . Min .

0 1 2 3 4 5 6 7 8 9 1 0 1 1 1 2 1 3 1 4 I S 1 6 1 7 I B 1 9 2 0 2 1 2 2 23 2 4 2 5 2 6 2 7 28 29 Second s 

### n 1 5 J U i b STEA

M PLUM E (chec ki f applicable ) Attache d Detache d COMMENT S COMPAN Y LOCATIO N TES TNUMBE R DAT E FIGUR

E 9- 2 OBSERVATIO

NRECOR D (Continued ) OBSERVE

R TYPE FACim T PAG E O F
POINT O F EMISSTSN T

•Hr . Min . Second s

"D ~ 3 0 i 3 1 32 33 3 4 35 36 37 3 8 39 4 0 4 1 4 2 4 3 44 45 46 4 7 4 8 49 50 5 1 52 53 5 4 5 5 56 5 7 5 8 59 1 5

i l i 1

< 

### 3 o 4 5 STEA

M PLUM E (chec kif

applicable ) Attache d. Detache d COMMENT S

[F B Doc.74-2616 0 File d11-11-74;3:4 S am ]^ 4 7

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### Inspectio nManua l fo r th e Enforcemen t

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### Yatendr aM . Sha han dJame s R . Burk e 9 . PERFORMIN GOR G\N IZAT IO NNAM EAN O AOORES S 

### PEDC o Environmental , Inc . 1149 9 Cheste r

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### Standard s o f

Performanc e fo r

ne w an dmodifie dcoa l preparatio n plant s .wer e promulgate dunde r Sectio n11 1 o f

th e Clea nAi r

Ac t o nJanuar y 15 , 1976 . Thi s repor t present s procedure s fo r in
- spectio no f

coa l preparatio nfacilitie s towar ddeterminatio n o f thei r complianc e wit hNSPS . I t als o provide s backgroun d informatio ntha t

wil l ai dth e inspecto r i nunderstandin g th e coa l preparatio nproces s an dth e effect s o f operatin g parameter s o nproces s emissions .

17 . KE Y WORD S AN O DOCUMEN TANALYSI S a . DESCRIPTOR S 

### Ai r Pollutio nContro l Coa l Preparatio n Verificatio nInspectio n Performanc e Test s

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### Unlimite d OUS.GOVERNMENTPRINTINGOFFtCE : 1977- 260 .880:10 4 b.lDENTIFIERS/OPE NENDE D TERM S 

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