P.1 

OAR Box 1105 

Prepped by Candice Davis 

Document Number: 

106)l-A-3 

Docket Number: 

A-80-26 

Printed 4/14/2008 3:11:59 PM Sheet 106 of 131 
P.2 

INSPECTION MANUAL FOR THE 

ENFORCEMENT OF NEW SOURCE 

PERFORMANCE STANDARDS: 

COAL PREPARATION PLANTS 

--;."- ,--,-,•' , -,ir.--nV 

i.:ii- - ..,..- - r ••'•," '•'"'•! j. . A ! -i^" 1 ^

i 

l!-';' \//}-- :'\-.'/Y 

Contract No. 68-01-3150 

EPA Project Officer: Mark Antell 

Prepared for: 

U.S. ENVIRONMENTAL PROTECTION AGENCY 

Division of Stationary Source Enforcement 

Washington, D.C. 

August 1977 
P.3 

This report was furnished to the U.S. Environmental Protection Agency by PEDCo Environmental, Inc., Cincinnati, Ohio, 

in fulfillment of Contract No% 68-01-3150. The contents of 

this report are reproduced herein as received from the 

contractor. The opinions, findings and conclusions expressed 

are those of the authors and not necessarily those of the 

U.S. Environmental Protection Agency. 

i 

i 

1 1 
P.4 

ACKNOWLEDGMENT 

This report was prepared for the U.S. Environmental 

Protection Agency by PEDCo Environmental, Inc., Cincinnati, 

Ohio. The Project Director was Mr. Timothy W. Devitt; the 

Project Manager, Mr. Yatendra M. Shah. Principal authors 

were Messrs. James R. Burke, Norman J. Kulujian, and Yatendra 

M. Shah. 

Mr. Mark Antell was Project Officer for the U.S. 

Environmental Protection Agency. The authors appreciate the 

contributions made to this study by Mr. Antell and other 

members of the U.S. Environmental Protection Agency. 

1 1 1 
P.5 

TABLE OF CONTENTS 

1.0 INTRODUCTION 

2.0 SUMMARY OF NSPS REGULATIONS 

2.1 Applicability and Designation of 

Affected Facility 

2.2 Definitions 

2.3 Emission Standards for Particulate Matter 

2.4 Monitoring of Operations 

2.5 Test Methods and Procedures 

3.0 COAL PREPARATION INDUSTRY 

3.1 Coal Markets 

3.2 Purpose of Coal Preparation 

3.3 Development of Mining Methods and Changing 

Preparation Standards 

3.4 Location of Coal Preparation Plants 

3.5 Economics of Coal Preparation 

4.0 PROCESS DESCRIPTION 

4.1 Capabilities of Coal Preparation 

4.2 Application of Cleaning Processes to 

Size Increments 

4.3 Coal Sizing 

4.4 Pneumatic Cleaning 

Page 

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 

v 
P.6 

TABLE OF CONTENTS (continued) 

Page 

4.5 Jig-Table Washing 4-12 

4.6 Heavy-Media Washing Plant 4-15 

4.7 Water Clarification Plant 4-19 

4.8 Thermal Drying 4-22 

4.9 Emission Sources and Control Devices 4-26 

4.10 Control Devices, Their Capabilities and 4-27 

Efficiencies 

5.0 INSTRUMENTATION AND RECORDS 5-1 

5.1 Process Instrumentation 5-2 

5.2 Records 5-5 

6.0 START-UP, SHUTDOWN, AND MALFUNCTIONS 6-1 

6.1 Start-up and Shutdown 6-1 

6.2 Changes in Coal Feed 6-3 

6.3 Malfunction of Support Equipment 6-4 

6.4 Malfunction in Sources of Fugitive Dust 6-5 

6.5 Malfunction of Control Devices 6-13 

7.0 EMISSION PERFORMANCE TESTS 7-1 

7.1 Pretest Procedures 7-1 

7.2 Test Monitoring 7-5 

8.0 PERIODIC COMPLIANCE INSPECTIONS 8-1 

8.1 Performing the Periodic Inspection 8-1 

8.2 Determining Compliance Status 8-13 

REFERENCES 8-15 

vi 

i 
P.7 

TABLE OF CONTENTS (continued) 

Page 

APPENDIX A NEW SOURCE PERFORMANCE STANDARDS A-1 

COAL PREPARATION PLANTS 

APPENDIX B STANDARD TEST METHODS B-1 

vi 1 
F 

P.8 

LIST OF FIGURES 

No. Page 

3-1 Trends in Coal Production and Coal Cleaning 3-6 

3-2 Illustrative Cleaning Circuit 3-10 

4-1 Coal Sizing Circuit 4-6 

4-2 Hammermill 4-7 

4-3 Rotary Breaker 4-7 

4-4 Pneumatic Cleaning Circuit 4-10 

4-5 Air Table 4-11 

4-6 Jig Table Cleaning Circuit 4-13 

4-7 Air-Pulsated Jig 4-14 

4-8 Deister Table 4-14 

4-9 Heavy-Media Cleaning Circuit 4-16 

4-10 Heavy-Media Cyclone 4-17 

4-11 Water Clarification Circuit 4-20 

4-12 Froth Flotation Unit 4-21 

4-13 Fluid-Bed Dryer 4-23 

4-14 Multilouver Dryer 4-24 

4-15 Cascade Dryer 4-24 

4-16 Flash Dryer 4-25 

v m 
P.9 

I 

LIST OF TABLES 

No. Page 

2-1 Comparison of NSPS and State Emission 2-5 

Regulations 

3-1 Location of Coal Washing Capacity and 3-8 

Bituminous/Lignite Coal Production 

3-2 Cost Analysis, Raw and Washed Coals 3-13 

3-3 Illustrative Preparation Costs, Eastern 3-15 

Kentucky Coals 

3-4 Illustrative Preparation Costs, West 3-17 

Virginia Coals 

4-1 Coal Size Ranges for Cleaning Equipment 4-4 

4-2 Cyclong Variables 4-28 

4-3 Scrubber Variables 4-29 

4-4 Orifice Flow Rates 4-30 

4-5 Operating Temperatures 4-31 

7-1 Emission Performance Test Responsibilities 7-6 

7-2 Checklist for Performance Test 7-7 

8-1 Checklist for Periodic Inspection 8-2 

ix 
P.10 

I 

X 

1.0 INTRODUCTION 

On October 24, 1974, under Section 111 of the Clean Air 

Act, as amended, the Environmental Protection Agency proposed standards of performance for new and modified coal 

preparation plants. The proposed standards were modified on 

the basis of comments received from various interested 

parties. The Federal Register of January 15, 1976, presents 

:| the standards of performance for new and modified coal 

I preparation plants. 

k This report presents procedures for inspection of coal 

I 

| preparation facilities toward determination of their comrt pliance with New Source Performance Standards (NSPS) . It 

] also provides background information that will aid the i 

inspector in understanding the coal preparation process and 

the effects of operating parameters on process emissions. 

Section 2.0 deals with the emission regulations for the 

coal preparation industry, presenting a brief history of 

NSPS, a discussion of the need for modifications of the 

proposed standards, and a summary of emission regulations, 

including monitoring and recordkeeping requirements. 

Regulations of individual states pertaining to coal preparation plants are compared with the NSPS. 

& 

1-1 
P.11 

Background information on the coal preparation industry 

is presented in Section 3.0, which describes the purpose of 

coal preparation, market requirements, market trends, geographic location of plants, and the economics of coal 

preparation. 

i Section 4.0 describes the coal preparation process and 

the major process variations, outlining the function of 

process equipment, the potential emission points, and the 

emission control techniques currently in use in the coal 

preparation industry. 

Instrumentation and record-keeping practices of the 

newer plants are discussed in Section 5.0. 

Section 6.0 deals with emissions that occur during 

start-up, shutdown, and malfunction, with operational 

procedures for maintaining such emissions at or below the 

required levels. 

Section 7.0 presents in detail the inspection procedure 

and check points for observation during performance tests. 

Test duration, operating conditions, and interpretation of 

instrument indications are discussed. 

Section 8.0 outlines periodic inspection procedures and 

the relationship of periodic inspection data to those obtained in the initial performance test. 

1-2 
P.12 

The NSPS as presented in the Federal Register are 

reproduced in Appendix A. Appendix B presents standard 

test procedures. 

1-3 
P.13 

$'• 

f 

2.0 SUMMARY OF NSPS REGULATIONS 

The following summary of New Source Performance Standards for coal preparation plants is given in a format 

corresponding to that used in the Federal Register, as 

reproduced in Appendix A. Regulations proposed by individual states are discussed briefly. 

2.1 APPLICABILITY AND DESIGNATION OF AFFECTED FACILITY 

Coal preparation plants processing less than 200 tons 

per day of coal are exempted by the NSPS. The affected 

facilities in the coal preparation plants processing more 

than 200 tons per day are thermal dryers, pneumatic coal 

cleaning equipment (air tables), coal processing and conveying equipment (including breakers and crushers), coal 

storage systems, and coal transfer and loading facilities. 

2.2 DEFINITIONS 

Underground mining operations are not considered part 

of the coal preparation process. Coal storage and transfer 

sources are governed by NSPS only if they form a part of the 

coal preparation facility; isolated coal storage and transfer 

stations are excluded. Open coal storage piles are excluded 

from the definition of coal storage systems. 

2-1 
P.M 

2.3 EMISSION STANDARDS FOR PARTICULATE MATTER 

Regulations for emissions of particulate matter from 

coal processing facilities are as follows: 

2.3.1 Thermal Dryer 

Exhaust gases discharged into atmosphere shall not 

contain particulate matter in excess of 0.070 gram/dry 

standard cubic meter (g/dscm) or 0.031 grain/dry standard 

cubic foot (gr/dscf) and shall not exhibit 20 percent or 

greater opacity. 

2.3.2 Pneumatic Coal Cleaning Equipment (Air Table) 

The gases discharged into atmosphere from an air table 

shall not contain particulate matter in excess of 0.040 

g/dscm (0.018 gr/dscf) and shall not exhibit 10 percent or 

greater opacity. 

2.3.3 Other Facilities 

The gases discharged into atmosphere from other coal 

conveying, processing, and storage and transfer facilities 

shall not exhibit 20 percent or greater opacity. 

2.4 MONITORING OF OPERATIONS 

The NSPS regulations require continuous monitoring of 

exit gas temperature on the thermal dryer. If a venturi 

scrubber is used to control emissions from the thermal 

dryer, continuous monitoring of water supply pressure and of 

pressure loss through the venturi constriction are required. 

i 

2-2 
P.15 

2.5 TEST METHODS AND PROCEDURES 

The regulations prescribe standard test methods and 

procedures for particulate emission measurements. Method 5 

is to be used for the concentration of particulate matter 

and associated moisture content, method 1 for sample and 

velocity traverse, method 2 for velocity and volumetric flow 

rate, and method 3 for gas analysis. The sampling time for 

method 5 is at least 60 minutes, and the minimum sample 

volume is 30.0 dscf. Sampling is not to be started until 30 

minutes after start-up and is to be terminated before shutdown procedures commence. Standard test methods are given 

in Appendix B. 

Most of the states have no separate emission regulations for coal preparation plants, which usually are encompassed under process emission regulations. Three eastern 

coal-producing states - Pennsylvania, Virginia, and West 

Virginia - and the State of New Mexico have formulated regulations for coal preparation plants. 

The Pennsylvania regulations state a single allowable 

emission rate of 0.02 gr/dscf for thermal dryers and air 

tables. The concentration for thermal dryers is more 

stringent than the NSPS allowable concentration of 0.031 

gr/dscf; the NSPS allowable emission rate for air tables is 

0.018 gr/dscf. The Virginia regulations allow 105 pounds 

2-3 
._EJfi_, 

per hour of particulate emissions from thermal dryers processing 200 tons per hour or more coal. Allowable emissions 

from the air table are 0.05 gr/dscf. The West Virginia 

regulations for thermal dryers installed after March 1, 

1970, range from 0.07 to 0.10 gr/dscf. Allowable emissions 

from an air table are 0.05 gr/dscf. New Mexico State regulations require good control of coal processing and conveying operations; no quantitative limits are specified. A 

comparison of NSPS regulations and these State regulations 

is presented in Table 2.1. 

2-4 
Table 2-1. NSPS AND STATE EMISSION REGULATIONS 

I 

Coal processing 

facility 

Thermal dryer 

Air table 

Processing and 

conveying 

NSPS 

0.031 gr/dscf 

Opacity: less than 

20 percent 

0.018 gr/dscf 

Opacity: less than 

10 percent 

Opacity: less than 

20 percent 

Particulate 

Pennsylvania 

0.020 gr/dscf 

0.020 gr/dscf 

No regulation 

matter emission regulation 

Virginia 

105 lb/hr 

0.05 gr/dscf 

No regulation 

West Virginia 

Gas flow, 

scfm 

75,000 or less 

111,000 or less 

163,000 or less 

240,000 or above 

gr/dscf 

0.10 

0.09 

0.08 

0.07 

0.05 gr/dscf 

Fugitive dust control 

system required 

New Mexico 

No regulation 

No regulation 

Fugitive dust control 

system required 
P.18 

b 

3.0 COAL PREPARATION INDUSTRY 

In the early part of this century efforts to prepare 

coal were directed to sizing the coal to supply lump coal 

for domestic use and intermediate sizes for industrial or 

bunker use; the fines were usually rejected as unfit for 

sale. Development of sizing facilities to meet the demands 

of the midcentury coal consumer resulted in highly sophisticated handling and screening facilities. Today's market 

requires less sizing than ever before, the primary limitation being maximum size for shipment. 

Since the very early days of mining, attempts have been 

made to improve the quality of coal by removing slate. These 

efforts were made in the underground mines until the advent 

of mechanical mining, supported by hand picking in the 

"tipple" outside the mine. The first washing was done in 

Baum and Norton jigs imported from Europe, followed by the 

introduction of the "Chance" washer in 1918. The latter was 

an excellent washer utilizing sand and water as a medium, 

which has since been displaced by the "heavy media" process 

using magnetite. Through the years, many other types of 

washers have been introduced and have been abandoned. 

3-1 
P.19 

I 

Jh= 

The means of drying have been improved, although the 

original screening equipment has been supplemented only by 

centrifuges. 

The adoption of Diester tables near the middle of the 

century to wash fine coal required supplementary equipment 

including centrifuges, froth flotation devices, disc filters, 

thickeners, cyclones, and thermal dryers. 

3.1 COAL MARKETS 

Until the middle of the dentury the primary coal 

markets were domestic, transportation (rail and ship), 

metallurgical, and industrial. At present the primary coal 

markets are for utility and metallurgical use and for 

export. The utility market uses low-quality coals. The 

metallurgical market requires the very best coals, completely prepared. The export market utilizes a quality 

somewhat lower than that of the metallurgical coals. 

3.2 PURPOSE OF COAL PREPARATION 

Coal preparation serves several purposes. One important 

purpose is to increase the heating value of the coal by 

mechanical removal of impurities. This is often required in 

order to find a market for the product. Run-of-mine coal 

from a modern mine may incorporate as much as 60 percent 

reject materials. 

3-2 
Air pollution control often requires partial removal of 

pyrites with the ash to reduce the sulfur content of the 

coal. Ash content often must be controlled to conform to a 

prescribed quality stipulated in contractual agreements. 

Because of firing characteristics, it is often as important 

to retain the ash content at a given level as it is to 

reduce it. 

Freight savings are substantial when impurities are 

removed prior to loading. Finally, the rejected impurities 

i 

i are more easily disposed of at the mine site remote from 

I 

| cities than at the burning site, which is usually in a 

% populated area. 

! 

il i 

% 

I 

i i 

3.3 DEVELOPMENT OF MINING METHODS AND CHANGING PREPARATION 

STANDARDS 

The earliest mining system used in England, from which 

U.S. practices evolved, was the longwall method. Mining 

could proceed from the shaft only a short distance because 

no forced ventilation was available. All the coal within 

this perimeter was removed prior to extending the shaft 

deeper or sinking a new one. No coal preparation of consequence was performed at this time. 

The room and pillar method was used in underground 

mines in this country because of the nature of and easy 

accessibility of the coal beds. Strip mining was introduced 

during the second decade of this century, after the develop3-3 
P.21 

I I 

ment of the steam shovel for the Panama Canal, and the 

longwall system was reintroduced on an experimental basis 

during the last 20 years. Auger mining was introduced with 

the spread of coal stripping, as a supporting method of 

recoving coals from underneath a highwall. 

Coal is produced currently by the following methods: 

Underground mining 45 percent 

Mined by hand 0.7 

Conventional mining 15.0 

Continuous mining 27.7 

Longwall mining 1.6 

Strip mining 55 percent 

Until World War II most coal was loaded by hand and was 

obtained from the better seams of coal. Each worker was 

responsible for rejecting impurities and (sometimes) fines 

in the mine. Outside preparation equipment consisted of 

screens, crushers, and picking tables. Washeries were not 

common. 

Exhaustion of the best coals and adoption of mechanical 

mining, which eliminated the removal of impurities in the 

mine, required the wider use of cleaning plants incorporating screens, crushers, picking tables, and washers. These 

plants normally practiced hand picking for the lump and egg 

sizes (more than 3 inches) and washed the coarser coal (3 

in. x 1/4 in.). The fine coal (1/4 x 0) was usually shipped 

raw. The reject from such a plant was unlikely to exceed 10 

percent of the run-of-mine (ROM) coal. 

3-4 
P.22 

fi 

Introduction of the continuous miner requiring "full 

seam" mining, elimination of a large portion of the domestic 

market, and further exhaustion of the best coals imposed 

further requirements on the coal preparation plants. They 

\l were required to clean and dry the 1/4 x 0 coal fraction, the 

If 

state of development that is current today. Picking tables 

have been eliminated, a fine-coal circuit has been added, 

and rejection of 50 percent of the ROM coal is not uncommon. 

Fluctuations in coal demand resulted in the dismantling 

of plants, some of which were incorporated into other or new 

plants, always of larger capacities. The trend has been to 

utilize one large plant to process coal from several mines, 

even from different seams, at the expense of additional 

freight charges and intensified refuse disposal requirements. Figure 3-1 indicates the trends in the coal preparation industry. 

Some plants, modified and expanded several times, are 

I 1|- still operating at the original site after 50 years, long 

after the original mine has been abandoned. 

3.4 LOCATION OF COAL PREPARATION PLANTS 

General Considerations 

Large coal washing plants are normally located in the 

mining areas to accommodate one or more mines. They are 

concentrated near the highest-quality coals because of 

process economics and market factors. 

3-5 
I 

l\J\J 

600 

500 

tn 400 z . o

 ( 

tD 

O 

„ 

« 300 

z f 

=3 COAL 

200 

100 

^~^\ 

-

>v 

-

ANNUAL COAL PRODUCTION ^ 

• 

COAL MECHANICALLY CLEANED 

-

-

-

-

1947 62 63 64 65 66 67 6« 69 70 71 72 73 74 75 

YEAR OF PRODUCTION 

Figure 3-1. Trends in coal production and coal cleaning, 
P.24 

?3 

A few washing plants located at river loading sites are 

served by railroads with raw coal from the mines and dispose 

of the refuse near the plant. 

Coal screening and crushing plants are sited at widely 

scattered locations wherever coal may be used, particularly 

at coke plants, coal yards, power plants, and industrial 

plants. They are also found at all mine loading sites. 

Table 3-1 gives locations of major plants. 

Siting Considerations 

Siting of coal preparation plants is based on the 

following considerations: 

a. Length of haul. Optimum location is at shortest 

possible distance from the mine. 

b. Access to transportation by railway or barge. 

c. Water supply. The plant must be provided with 

substantial amounts of water from wells, streams, 

or impoundments. 

d. Suitable terrain. Level areas are required for 

thickeners and slurry ponds; large areas must be 

suitable for refuse disposal. 

Transportation of Raw Material 

A shaft mine discharges coal directly into the plant 

without intermediate transportation. 

Coal is also delivered directly from the mine by belt 

conveyor or mine cars when the plant is adjacent to the mine 

mouth. 

3-7 
Table 3-1. LOCATION OF COAL WASHING CAPACITY Ai. 

BITUMINOUS/LIGNITE COAL PRODUCTION 

State 

Alabama 

Alaska 

Arizona 

Arkansas 

Colorado 

Illinois 

Indiana 

Iowa 

Kansas 

Kentucky 

Maryland 

Missouri 

Montana 

New Mexico 

North Dakota 

Ohio 

Oklahoma 

Pennsylvania 

Tennessee 

Texas 

Utah 

Virginia 

Washington 

West Virginia 

Wyoming 

Total 

Production 

capacity 

1974, 

thousand tons 

19,745 

716 

6,432 

445 

6,960 

58,080 

25,267 

680 

679 

133,000 

2,170 

4,625 

14,089 

9,669 

7,400 

44,566 

2,375 

78,879 

7,681 

7,684 

6,047 

33,249 

3,915 

105,997 

20,650 

601,000 

No. 

operating 

companies 

36 

1 

1 

4 

11 

• 14 

12 

7 

2 

338 

12 

3 

5 

3 

5 

73 

7 

220 

46 

2 

10 

69 

3 

222 

14 

•1,120 

No. 

washing 

plants 

21 

3 

36 

9 

2 

69 

1 

2 

1 

20 

64 

5 

5 

43 

1 

106 

1 

389 

3-8 
P.26 

( 

\ 

• f 

Central cleaning plants are served by trucks, which may 

haul coal 20 miles from the mine, and by railcars, which 

haul raw coal to the plant and then reload with clean coal. 

"Overland" conveyors haul coal from the mine to the 

plant over distances up to 10 miles. One installation moves 

coal from mine to plant by pipeline in a water medium. 

Transportation of Plant Products 

Refuse from coal preparation usually is hauled to 

disposal areas by trucks. It is sometimes moved to adjacent 

valleys by belt conveyors and aerial tramways. 

Prepared coal is removed from the plant by railway, 

barge, and truck. A small part is transported by conveyors 

to power plant stockpiles or to loading terminals for longdistance shipment. 

3.5 ECONOMICS OF COAL PREPARATION 

The advantages of preparing coal vary with the seam 

being mined, the type of mining, and potential markets. 

Figure 3-2 demonstrates the improvements made in the coal 

that could be mined from a coal seam by continuous miners in 

Indiana, Pennsylvania. This illustration represents an 

extreme case in coal mining and preparation. Large amounts 

of slate in the ROM material result in a heating value (HV) 

of 7580 Btu, which is too low for commercial sale. Rejection 

of impurities produces a product containing 6.6 percent ash 

3-
RAW COAL IOO* 

» - i 

CLEAN COAL 54.5% 

RAW COAL 

CLEAN COAL 

REFUSE 

Figur e 3-2 . 

100.0 

54.5 

45.5 

HHV 

BTU/LB 

7560 

13308 

675 

Illustrativ e cl e 

* 

ASH 

48.4 

6.6 

98.5 

anin g 

TOTAL 

HEAT 

CONTENT 

7560 

7253 

307 

circui t 

REFUSE 45.S% 

% 

S 

5.0 

2.2 

8.3 6 

3-10 
with a heating value of 13,300 Btu; such a coal is readily 

marketable. 

The capacity of a boiler is upgraded by use of highheat-content coal, offering indirect savings in capital 

investment, operation, and maintenance. 

The sizes of stockpiles at large points of consumption 

are based on a required period of operation without replenishment. This requirement can be eas*ily translated into a 

given amount of stored energy (Btu). Because a stockpile 

containing high-Btu coal can be smaller than one containing 

low-Btu coal, the costs of materials handling are lower. In 

the case depicted in Figure 3-2, a given stockpile of ROM 

coal would be 1.76 times larger than a pile of prepared coal 

having the same total heating value. Rejects from a cleaning 

plant are directly correlated to the ash produced in a power 

plant. The rejects from a cleaning plant are much easier to 

dispose of than is the ash from a power plant, and a substantial savings can be realized where disposal is done at 

the cleaning plant. A power plant using the coal evaluated 

in Fiqure 3-2 (45.5 percent reject) would be required to 

handle 7.24 times as much ash if the coal were burned raw 

rather than washed. Rejecting impurities at the mine 

results in a direct freight savings. 

3-11 
P.29 

I i 

Two cases, illustrating use of raw and washed coal from 

the same mine, are analyzed in Table 3-2. Case 1 asseses 

the value of ROM coal that is shipped 200 miles to a power 

plant and sold for $0.70/10 Btu. Case II assesses the 

value of the ROM coal that is washed and shipped to the same 

plant for the same price. 

Coal preparation involves five different steps, combinations of which constitute the plant for a given mine. 

i Step 1 - Crushing/screening. This step involves no 

1 !> quality improvement, merely sizing for raw shipment. Most 

t 

' j 

j utility coal is prepared this way. If further preparation I 

U is involved, a separation is made at 1/4-3/8 inch. 

This step includes all coal shipped. Costs are less 

than those of other steps, ranging from $0.15 to $0.30 per 

ton. 

Step 2 - Wet washing the +l/4-inch sizes. Approximately 78 percent of all cleaned coal is washed by this 

means. Many plants use only this step, shipping the 1/4 x 0 

size raw. 

Cost of wet washing the +l/4-inch coal ranges from 

$0.25 to $0.50 per ton of feed. 

Step 3 - Wet washing 1/4-inch x 28M (28 Mesh). Although 

not usually practiced elsewhere, this step is nearly always 

used at large underground mines. Approximately 14 percent 

of the cleaned coal is washed by this means. 

3-12 
P.30 

Table 3-2. COST ANALYSIS, RAW AND WASHED COALS 

" . , . 72000x7580 Btu x $0.70 , .i n ,, 

Purchase cost 1 ton ( 7 ) = $10.61 

10° Btu 

Freight 200 miles (1 ton x 200 Mi. x $0,009 ) = 1.80 

Stockpile cost = 1.20 

Ash disposal (45.5% x $3.80°) = 1.73 

$15.34 

Actual cost of energy at bunker 2000 7500 = $1.01/10 Btu 

Case II - Washed coal to power plant. 

T . , . „_.. ,2000 x 13310 x 0.545 x 0.70, TTTT7" Purchase cost 1 ton ROM ( 7 ) = $10.15 

I

 10 

Freight 200 miles (0.545 x 200 x 0.009) = 0.98 

c Washing cost = 1.60 

Refuse disposal (0.455 x $1.20°) = 0.54 

Stockpile cost (1.20 x 0.545) = 0.65 

Ash disposal (3.80 x 0.545 x 6.6%) = 0.13 

$14.05 

Actual cost of energy at bunker ( 2QOO—^72~53^

 = $0.97/10 Btu 

For this analysis the HV is below acceptable values. The 

price is below mining cost. 

Typical Midwest unit train rate, 200 MM ton mi/yr. 

c 

Typical average cost. 

3-13 
P.31 

Cost of this process ranges from $0.4 0 to $0.70 per ton 

of feed. 

Dry cleaning of the 1/4 x 0 coal with air tables accounts 

for only 5 percent of all coal cleaned. It is sometimes 

accompanied by prethermal drying. 

Cost of dry cleaning is between $0.20 and $0.4 0 per ton 

of feed. Thermal drying involves an additional cost. 

Step 4 - Wet washing the.2 8M x 0, the least common 

method, is used with only 3 percent of the coal and is 

usually restricted to large deep mines equipped with continuous miners. 

Costs range from $0.40 to $0.80 per ton of feed. 

Step 5 - Thermal drying is nearly always restricted to 

1/4 x 0 size coal, the exceptions being applications to 

predry coal for screening prior to cleaning on air tables. 

Cost of drying ranges from $0.60 to $1.20 per ton of 

feed. 

Costs for each step apply only to that portion of the 

feed that is affected, as indicated in Tables 3-3 and J-4. 

Costs of coal preparation are dependent on screen analysis 

and amount of rejects as well as efficiency of operation and 

design/condition of plant. 

The cost of processing in each step shown in the tables 

is the average of the cost ranges listed above. Table 3-3 

3-14 
Table 3-3. ILLUSTRATIVE PREPARATION COSTS, 

EASTERN KENTUCKY COALS 

OJ 

I 

ts. 

Size 

Raw coal 

+ 1/4 in. 

1/4 x 28M 

28M x 0 

Percent of 

total coal 

100.0 

51.1 

36.2 

12.7 

100.0 

Cost, $/ton 

screening 

0.225 

washing 

0.375 

0.55 

0.60 

Percent 

recovery 

100.0 

75.0 

78.6 

80.4 

Percent of 

clean coal 

38.3 

28.5 

10.2 

77.0 

Drying 

cost, $/ton 

0.90 

0.90 

Cost of 

preparation, 

$/ton 

0.225 

0.191 

0.199) 

0.256) 

0.076) 

0.090) 

1.037 

Cost of preparation/ton of clean coal = $1,037 — 0.77 = $1.34/ton 
P.33 

portrays coal from eastern Kentucky mined by conventional 

methods; Table 3-4 portrays coal from southern West Virginia 

mined by continuous mining methods. 

3-16 
Table 3-4. ILLUSTRATIVE PREPARATION COSTS, 

WEST VIRGINIA COALS 

Size 

Raw coal 

f + 1/4 in. 

1/4 x 28M 

28M x 0 

Percent of 

total coal 

100.0 

15.0 

65.7 

19.3 

100.0 

Cost. $/ton 

screening 

0.225 

washing 

0.375 

0.55 

0.60 

Recovery 

100.0 

41.0 

68.1 

69.1 

Percent of 

clean coal 

6.1 

44.7 

13.4 

64.2 

Drying cost, 

$/ton 

0.90 

0.90 

Total 

preparation 

cost, $/ton 

0.225 

0.056 

0.361) 

0.402) 

0.116) 

0.120) 

1.280 

Cost of preparation/ton of clean coal = $1.28 ^_ 0.642 = $1.99/ton 
4.0 PROCESS DESCRIPTION 

-Si $ 

£ 

As it leaves the mine, coal varies widely in size, ash 

content, moisture content, and sulfur content. These are 

the characteristics that can be controlled by preparation. 

Sizes range upward to that of foreign materials, such 

as a chunk of rock that has fallen from the mine roof or a 

metal tie; large pieces of coal from a very hard seam are 

sometimes included. 

Ash content ranges from 3 to 60 percent at different 

mines. Most of the ash is introduced from the roof or 

bottom of the mine or from partings (small seams of slate) 

in the coal seam. This ash, called extraneous ash, is 

heavier than 1.80 specific gravity. The remaining ash is 

inherent in the coal. The density of the coal increases 

with the amount of ash present. 

The moisture content of the coal is also of two types. 

The surface moisture, that which was introduced after the 

coal was broken loose from the seam, is the easier to 

remove. This moisture is introduced by exposure to air, wet 

mining conditions, rainfall (in stockpiles), and water 

sprays. The remaining moisture, called "bed", "cellular," 

or "inherent" moisture, can be removed only by coking or 

M • 

4-1 
combustion. This moisture was included during formation of 

the coal. j. 

Foreign materials are introduced into the coal during 

the mining process, the most common being roof bolts, ties, 

car wheels, timber, shot wires, and cutting bits. 

Sulfur in coal occurs as sulfates, organic sulfur, and 

pyrites (sulfides of iron). The sulfates usually are present 

in small quantities and are not considered a problem. Organic 

sulfur is bound molecularly into the coal and is not removable by typical coal preparation processes. Pyrites generally are present in the form of modules or may be more 

intimately mixed with the coal. Coal preparation plants 

remove only a portion of the pyritic sulfur; therefore the 

degree of sulfur reduction depends on the percentage of 

pyrites in the coal, the degree to which this is intimately 

mixed with the coal, and extent of coal preparation. 

All the materials described above are combined with the 

coal to form the run of mine (ROM) feed. Coal, as referred 

to above, denotes the portion of the feed that is desired 

for utilization. 

4.1 CAPABILITIES OF COAL PREPARATION 

Coal preparation processes can improve the ROM coal to 

meet market demands, as limited by the inherent characteristics of a given coal. 

4-2 
P.37 

II 

i 

I 

The top size of the ROM can be reduced to any size 

specified, although control of the varying size increments 

can be poor, dependent on the amount of crushing required. 

No practical technology is known for increasing the sizes of 

coal as mined. 

All extraneous ash can be removed. The limiting 

factor for removal of the remainder is an economic one. The 

percentage of rejects of coal must not reach a point that 

precludes a profit on the operation. The coal from better 

seams can be processed to a reasonable ash content with few 

rejects. That from a poor seam will be unable to match the 

ash content without excessive losses. The optimum level of 

removing the inherent ash sometimes depends upon the percentage of the refuse material having specific gravities of 1.3 

or lower. 

Although inherent moisture cannot be changed, the 

surface moisture can be reduced to any level that is economically practicable. Considerations include the possibility 

of reexposure to moisture during shipment and subsequent 

storage and the fact that intense thermal drying creates 

ideal conditions for readsorption of moisture. 

The free sulfur in the coal is subject to removal only 

by chemical treatment, which is not a coal preparation 

process, or by combustion. The reason that the pyrites can 

4-3 
be partially removed in washing processes is that they are 

heavy enough to be removed with the ash. The processes can 

remove only 30 to 60 percent of the pyrites, however, because 

some pyrites are not broken free of the coal and are present 

in a given piece in a quantity too small to increase its 

weight enough to be rejected. 

Foreign metals can be removed easily. Most wood fragments can be removed, although a few small pieces of wood 

cause no particular harm because they are combustible. 

4.2 APPLICATION OF CLEANING PROCESSES TO SIZE INCREMENTS 

Different types of mechanical cleaning apparatus are 

required for cleaning of coals in different size ranges. 

Coal larger than 8 inches is usually crushed to a smaller 

size; when lump coal is required, the large fraction is 

cleaned by slate pickers. The nominal size ranges and the 

applicable cleaning equipment are listed in Table 4-1. 

Table 4-1. COAL SIZE RANGES FOR CLEANING EQUIPMENT 

+ 8 

8 x 

1/4 

48M 

inches 

1/4 

x 4 8M 

x 0 

Picking tables 

Heavy media bath or drums 

Jigs 

Diester tables 

Heavy media cyclones 

Air tables 

Froth flotation 

Use of thermal dryers is usually restricted to the two 

smaller size fractions. Occasionally the + 1/4-inch fraction is dried to permit screening. 

4-4 
P.39 

i I 

4.3 COAL SIZING 

The first operations performed on ROM coal are removal 

of tramp iron and reduction of size to permit mechanical 

processing. The schematic of coal sizing circuit is shown 

in Figure 4-1. 

The ROM coal is first exposed to a high-intensity 

magnet, usually suspended over the incoming belt conveyor, 

which pulls the iron impurities out of the coal. This 

magnet sometimes follows the breaker but always precedes a 

screen-crusher. 

The coal then goes to the breaker, which is a large 

cylindrical shell with interior lifting blades; the shell is 

perforated with holes (2- to 8-inch diameter) to permit 

passage of small material. The breaker rotates on a horizontal axis, receiving material in one end, tumbling it as 

it passes through, breaking the soft material (coal), which 

passes through the holes in the shell, and permitting the 

hard, large, unbroken material to pass out the rear. The 

small material (-4 inches) goes to the cleaning plant, and 

the large rejected material falls into a bin to be hauled 

away. 

Various types of crushers are available for coal 

crushing. The hammermill, shown in Figure 4-2, and the 

rotary breaker, shown in Figure 4-3, are most commonly used. 

4-5 
P.40 

CAR DUMP 

A 

TRUCK DUMP 

A 

A FUGITIVE 

DUST 

A EMISSION POINTS 

BARGE 

LOADING 

A 

Figure 4-1. Coal sizing circuit. 

4-6 
P.41 

Figure 4-2. Hammermill. 

Figure 4-3. Rotary breaker, 

4-7 
P.42 

An alternate flow directs the ROM coal to a scalping 

screen, from which the oversize material (+ 4 inches) falls 

to a crusher, where it is reduced to -4 inches and is 

recombined with the screen underflow for transportation to 

the cleaning plant. This system is used more than the 

breaker but is somewhat vulnerable to large pieces which 

pass through the crusher and must be removed in a later 

process. The crusher most commonly used for this purpose is 

a heavy-duty single roll with tramp iron protection. 

Double rolls are more difficult to maintain in this 

heavy service, are more expensive, and offer no particular 

advantage. Slow-speed hammermills or impactors are more 

difficult to maintain, and jaw crushers have not been 

required. 

The raw coal is sometimes stored, prior to washing, to 

allow optimum scheduling of mine and plant operations. Open 

storage is the most common; silos are also used. 

At mines using unit train shipment, prepared coal is 

stored to accumulate enough to fill a train. For this 

purpose, silos are used most often to prevent accumulation 

of moisture and exposure to wind. Some open storage is also 

practiced. At other mines, cars or barges are loaded 

directly as the coal is processed, received, and shipped 

each day. 

4-8 
P.43 

I I 

- t 

II 

4.4 PNEUMATIC CLEANING 

Pneumatic cleaning devices, or air tables, are applied 

to the small fractions (-3/8 inches). In these devices 

currents of air flow upward through a perforated bottom 

plate over which a layer of coal passes. The extreme fines 

are entrapped in the air and must be recaptured by cyclones 

and bag filters for return without quality improvement. As 

the coal reaches the end of the tables, the bottom layer is 

heavy (high-ash) material, a center layer is medium-weight 

coal and bone (high-ash), and the top layer is coal (lowash) . The middle layer must be incorporated with the refuse 

(and rewashed) or with the coal. A typical pneumatic 

cleaning circuit is shown in Figure 4-4. The cross-sectional view of an air table is shown in Figure 4-5. 

The efficiency of these devices is poor. Their ability 

to remove ash is limited to 2 to 3 percent, regardless of 

how much is present. These devices represent the lowest 

capital investment of all cleaning devices, and they entail 

no problems of water supply and disposal. 

The incoming coal must be screened, and, because feed 

to the tables must be dry, thermal drying of the raw feed is 

required at some plants. The thermal dryers, in turn, 

require cyclones and scrubbers for control of particulate 

emissions. Thermal dryers are fired with coal, oil, or gas. 

4-9 
P.44 

2 X 3/8 •*• 

RAW 2 X 0 

A, 

SURGE 

BIN 

YENT TO 

ATMOSPHERE PRIMARY AIR 

TO LOADING OR WET CLEANING 

325 M X 0 

B VENT TO 

*" ATMOSPHERE 

SCRUBBER 

»2 X 0. 

H G

3

- -: 

^^MBUS COMBUST. AIR 1 

2i 

COMBUST. 

CHAMBER 

DRYING 

CHAMBER] 

100 M X 0 

Y_ 

SLURRY TO 

PONDS 

1/4 X 325 M 

CYCLONE 

BAG .---_ 

FILTERW W 

I • r' 

3/8 X 0 

3/8 X 0 

A J : 

CYCLONE 

2 X 325M - A 

—*1 SCREEN 

fc^g^ 2 X 3/8 

m 

CM 

eo 

x 

00 

•». 

CO 

c 

AIR TABLE 

A EMISSION POINTS 

B STACK EMISSIONS 

^7 

REFUSE 

BIN 

Figure 4-4. Pneumatic cleaning circuit. 

4-10 
P.45 

N V^i'B^^FEED 

V VvHV 

CLEAN COAL 

MOTOR 

SHAKER UNIT 

SPEED REDUCER 

REFUSE FLUTTEF 

VALVE 

HUTCH 

Figure 4-5. Air table . 

4-11 
4.5 JIG-TABLE WASHING 

Jig-table washing plants are thus named because jigs 

are used to clean the +l/4-inch increment and Diester tables 

to clean the 1/4 inch x 28M increment. Froth cells and/or 

thermal dryers may be used in conjunction with this equipment. Figure 4-6 shows a coal cleaning circuit with jig 

table. The air-pulsated coal jig is shown in Figure 4-7, 

the Deister coal washing table is shown in Figure 4-8. 

The raw coal, restricted to sizes smaller than 8 

inches, is separated on a wet screen (usually 1/4-inch 

mesh). The large-sized increment goes into the jig; the 

remaining coal is sent to a separate cleaning circuit. The 

coal is dewatered on screens and in centrifuges, crushed to 

the desired size, and loaded. The jig makes the "equivalent" 

gravity separation on the principles of settling in rising 

and falling currents. The small-sized coal (-1/4 inch) is 

combined with the proper amount of water and distributed to 

the tables, where the refuse is separated from the coal. 

The refuse is dewatered on a screen and discarded. The 

clean coal is dewatered on a sieve bend (a stationary 

gravity screen), where the extreme fines are removed and 

discharged into a centrifuge for final dewatering and 

removal of the fines. The clean coal (+28M) is then loaded 

or conveyed to a thermal dryer. The Diester table is a 

4-12 
P.47 

SCREEN f 

REFUSE 4X 0 

co 

CM 

RAW COAL J—I—* 

BAUM JIG 

4_X 1/4 

~~*} SCREEN 

1/4 X 0 

1 1/2 X 

1/4 •CENTRIFUGE 

1/4 X 28M\ ^

 STM) 

SCREEN 

28M X 0 

1/4 X 28M 28M X 

f*fc£\ 

V 

REFUSE BIN ( 

.1/4 X 28M 

CENTRIFUGE 

\ X 28M 

A 

W CRUSHER 

1 

1 1/2 X 1/4 

CYCLONE, H 

cc 

UJ 

• \z 

) * 

V (D 

28M X 200IOM M • r-J 

1/4 X 200M 

T 

CLEAN COAL 

A 

j 1 

, THERMAL 

*1 DRYING 

j PLANT 

I 

I 

(1) TO WATER CLARIFICATION 

A POINTS OF EMISSION 

1/2 X 0 

1/2 X 0 

1/2 X 0 

CLEAN COAL LOADING 

OR STORAGE 

Figure 4-6. Jig tabl e cleaning circuit . 

4-13 
P.48 

A"^! /'-S ft-. 

Figure 4-7. Air-pulsated Dig, 

Figure 4-8. Deister table. 

4-14 
P.49 

1 | 

1 ' I 

flat, "riffled" surface, approximately 12 feet square, which 

oscillates perpendicular to the "riffles," in the direction 

of the flow of coal. The heavy rejects are discharged off 

one end of the discharge side of the table, the light coal 

is discharged from the opposite end, and the "middlings" are 

distributed between. 

The slurry produced, along with the fines, requires 

clarification before recirculation is feasible. Clarification is described in Section 4.7 and portrayed in 

Figure 4-11. 

4.6 HEAVY-MEDIA WASHING PLANT 

In a heavy-media washing plant, all the cleaning is 

done by flotation in a medium of selected specific gravity, 

maintained by a dispersion of finely ground magnetite in 

water. The plant is depicted in Figure 4-9. A schematic of 

a typical heavy-media cyclone is shown in Figure 4-10. 

The incoming raw coal is separated at 1/4 inch on an 

inclined screen. The "overs" proceed to a flat "prewet" 

screen, where the fine dust particles are sprayed off from 

the +1/4-inch coal. This increment is discharged into a 

heavy-medium vessel or bath, where the refuse is separated 

from the coal. The refuse is discharged to a "refuse rinse" 

screen, where it is dewatered. The freed medium is divided 

into two parts, one returning directly to circulation via 

the heavy-medium sump and the other pumped to magnetite 

4-15 
P.50 

4 X 1/4 

11/2X 0 

TO REFUSE BIN 

(A 

\l 

(D 

(E 

(F is 

(I 

RAW COAL SCREEN 

PRE WET SCREEN LOADING OR STORAGE 

(0) COARSE MAG. SEPAR. CLEAN COAL 

(K) FINE MAG. SEPAR. A 

(L) CENTRIFUGE 

REF. RINSE SCREEN (M) CENTRIFUGE 

COAL RINSE SCREEN (N) CENTRIFUGE 

SLURRY SCREEN (P) CRUSHER 

REFUSE RINSE SCREEN (R) CYCLONE 

SIEVE BEND (S) LIGHT MEDIA SUMP 

HVY. MEDIA BATH (T) HEAVY MEDIA SUMP 

HVY. MEDIA CYCLONE (V) HEAVY MEDIA SUMP 

A EMISSION POINTS 

(1) TO WATER CLARIFICATION 

Figure 4-9. Heavy-media cleaning circuit. 

4-16 
P.51 

L 

3 

i 

i 

tj 

i 

-t 

•& 

V 

i 

I 

! 

1: 

l 

i 

if 

1 

••'r 

•'fji 

J 

/ 

-

: 

I' 

i 

i 

f \ 

* 

6"\ { 

F i g 

•4 

ure 4-10. 

i 

^^^7^7-]. 1 ^V *\ \ \ 

A'r" » 

— t o

 w 

Heavy-media eye 

\ t 

lone . 

4-17 
P.52 

recovery. The refuse is discharged from the screen for 

disposal. The coal is discharged from the washer to a coalrinse screen, where the coal is dewatered and the medium is 

treated as from the refuse screen. The clean coal is then 

centrifuged, crushed, and loaded. The fine coal (-1/4 inch) 

from the raw coal screens is combined with magnetite and 

water and pumped to a heavy-media cyclone, where the refuse 

is separated from the coal by cyclonic action. The medium 

for this use is different from the one used in the heavymedia vessel in that the magnetite is finer and the effective specific gravity is different. The refuse is dewatered 

and the medium is recovered, as in the coarse coal section. 

The coal is discharged over a sieve bend and then proceeds 

to a centrifuge for final dewatering prior to transfer to a 

thermal dryer or to loading. 

Because the magnetite recovered from the rinse screens 

is diluted by sprays, it is processed in magnetic separators 

for recovery of the solid mineral. Each washer (bath and 

cyclone) retains its own recovery system, which includes 

sumps, pumps, and magnetic separators. The separator is a 

shaft-mounted steel drum containing an interior fixed 

magnet. The cylinder rotates within a vessel containing 

coal slurry and magnetite, retrieving solid magnetite from 

the slurry by virtue of the magnetic qualities of the 

magnetite and the magnetic field within the drum. 

4-18 

.4 
P.53_ 

) 

\ 

The effluent from the centrifuges contains -28M coal, 

broken from larger pieces of clean coal. This material is 

thickened in a cyclone, deslimed on a screen, and centrifuged prior to loading. 

4.7 WATER CLARIFICATION PLANT 

The water clarification plant receives all the slurry 

from the washing plant, separates the 4 8M x 0 fraction for 

cleaning, and returns the water for reuse. A typical 

clarification plant is shown in Figure 4-11. The 48M x 0 

fraction flows to froth flotation cells, where it is mixed 

thoroughly with a reagent (light oil). The coal accepts a 

coating of oil and floats off the top of the liquid to a 

disc filter, where the excess water is drawn through a 

fabric by a vacuum. The water is recirculated to the 

washery, and the fine coal is transported to loading or to 

a dryer. Figure 4-12 shows the froth flotation unit. 

The refuse does not accept the oil coating and sinks, 

to be removed with most of the incoming water to a static 

thickener. The thickener is a large, circular, open tank, 

which retains the water long enough to permit the particles 

of refuse to sink to the bottom. Clarified water is removed 

from the surface by "skimming troughs" around the perimeter 

of the tank and is recirculated to the cleaning plant. 

The tank is equipped with a rotating rake, which rakes 

the fine refuse from the bottom of the tank to the center of 

4-19 
P.54 

28M X 0 

48M X 0 

RAW COAL 

SLURRY 

48 X 28M^ RETURN TO •• 

(CYCLONE 

1 f 

'DO' 

REFUSE 

WASHING CIRCUIT 

CLEAN 

FLOTATION CELLS 

COAL 

DISC FILTER 

CHAM CM L CLARIFIED WATER 

RETURN TO THERMAL RETURN TO 

DRYER OR LOADING CIRCUIT 

2 

>-

o 

z 

LU 

CH 

TO STREAM.

 0VERFL0W 

k2\ 

DISC FILTER TJ 

REFUSE 

Figure 4-11. Water clarification circuit. 

JII, 4-20 
..... -!. . . ..^ f 

fiiH$it,m.?vt--} A£r&-ar.vi.**...:..*.~. • yy-^mmm^rT'^^ 

FEED 

I 

NJ 

#i rih "g^T 

CONCENTRATE 

Kscs: 

T T T T t T TT T » T T » T T » T t 

R 

CONCENTRATE 

FEED BOX INTERMEDIATE BOX DIRECT CONNECTION 

Figure 4-12. Froth flotation unit. 
I 

I • 

the tank, where it is collected by a pump and transferred to 

a disc filter. The filter removes part of the water for 

recirculation and discharges the solids as refuse. 

4.8 THERMAL DRYING 

The clean coal from various wet cleaning processes is 

wet and requires drying to make it suitable for transportation and final consumption. Thermal drying is employed to 

dry the wet coal. 

Drying in the thermal dryer is achieved by a direct 

contact between the wet coal and currents of hot combustion 

gases. Various dryers marketed by different manufacturers 

work on the same basic principle. 

The most common types of dryers are shown in Figures 

4-13 through 4-16. 

The fluid-bed dryer is shown in Figure 4-13. The dryer 

operates under negative pressure in which drying gases are 

drawn from the heat source through a fluidizing chamber. 

Dryer and furnace temperature controllers are employed in 

the control system to readjust the heat input to match the 

evaporative load changes. 

The multilouver dryer, shown in Figure 4-14 is suitable 

for large volumes and for the coals requiring rapid drying. 

The coal is carried up in the flights and then flows downward in a shallow bed over the ascending flights. It gradu4-22 
P.57 

FAN STACK 

.FAN 

DUST COLLECTOR 

DUST BIN-V 

DUST SCREW CONVEYORSETTLING CHAMBER 

DISCHARGE VALVE 

AUTOMATICALLY CONTROLLED 

FEED AND DISCHARGE GATES 

ROLL FEEDER 

' 

TEMPERING AIR DAMPER 

FURNACE 

BY-PASS STACK 

i 

Table 4-13. Fluid-bed dryer. 

4-23 
P.58 

Figure 4-14. Multilouver dryer, 

Figure 4-15. Cascade dryer. 

t; 

4-24 
P.59 

ALTERNATE VENT 

WET SCRUBBER 

(IF REQUIRED) 

C-E RAYMOND FLASH DRYING 

ALTERNATE ARRANGEMENT 

FOR VERY FINE WET COAL 

DRY COAL DISCHARGE 

FROM AIR LOCK^ ^ 

AUTOMATIC—2/Tl 

DRY DIVIDER

 M u 

DRY RETURNWET FEED 

MIXER 

-DRYING COLUMN 

DRY COAL CONVEYOR 

-WET FEED CONVEYOR 

WET FEED BIN 

-GATE 

WET FEEDER 

-DOUBLE FLAP VALVE 

TEMPERING AIR DAMPER 

Figure 4-16. Flash dryer. 

4-25 
P.60 

ally moves across the dryer, a little at each pass, from the 

feed point to the discharge point. 

The cascade dryer is shown in Figure 4-15. The wet 

coal is fed to the dryer by a rotary feeder; as the shelves 

in the dryer vibrate, the coal cascades down through them 

and is collected in a conveyor at the bottom for evacuation. 

Hot gases are drawn upward through and between the wedge 

wire shelves. 

The flash dryer is shown in Figure 4-16. The term 

"flash" is derived from the fact that the wet coal is 

continuously introduced into a column of high-temperature 

gases and moisture removal is practically instantaneous. 

4.9 EMISSION SOURCES AND CONTROL DEVICES 

All emission sources are subject to opacity regulations 

and two are subject to particulate count regulations. The 

pneumatic cleaning plants generate emissions from the air 

tables and are subject to one standard; thermal dryers have 

an emission stack and are subject to another standard. 

Emission points in the various plant sections are shown 

in the appropriate diagrams. The most commonly used control 

devices for each emission point are keyed as follows: 

(1) Cyclone 

(2) Scrubber 

(3) Spray 

(4) Baghouse or fabric filter 

(5) Enclosure 

4-26 
P.61 

These parenthetical numbers are used in the following 

tabulation relating emission sources and their controls. 

Coal Handling Facilities 

RR and mine car dumps - 2,3,5 

Truck dumps - 2,3,5 

Storage bins and silos - 4,5 

Breakers and crushers - 3,4,5 

Conveyor transfer points - 3,4,5 

Screens - 4,5 

Trucks, RR car, and barge loading stations - 1/4,5 

Pneumatic Cleaning Plant 

Surge bin -4, 5 

Thermal dryer stack (if present) - 1,2 

Vibrating screens - 4,5 

Air tables 1,4,5 

Crusher - 3,4,5 

Jig-Table Washing Plant 

Screen - 4,5 

Loading facility - 2,3,5 

Thermal dryer (if present) - 1,2 

Heavy-Media Washing Plant 

Screen - 4,5 

Loading facility - 2,3,5 

Thermal dryer (if present) - 1,2 

4.10 CONTROL DEVICES, THEIR CAPABILITIES AND EFFICIENCIES 

The various control devices are employed singly or in 

combination at each emission point according to the temperatures and volumes of flue gases, the degree of contamination, and the applicable regulations. 

Cyclone sizes range from 2 inches to 18 feet in diameter, 

the smaller being applied in groups that use a common inlet 

4-27 
P.62 

and dust hopper. A cyclone serves as a primary separator 

because its efficiency is limited to particles larger than 

44 microns. The efficiency is a function of the particle 

mass, inlet velocity, and the radius of the cyclone, increasing with smaller radii and higher inlet velocities. 

Pressure drop also increases with velocity. 

Some variables of cyclone design are indicated in Table 

4-2. 

Min. 

Max. 

Cyc. 

dia. 

2 in. 

18 ft. 

Table 4-2 

Capacity, 

cfm 

10 

25,000 

. CYCLONE 

Inlet 

velocity, 

fps 

15 

75 

VARIABLES 

Pressure 

drop, in. 

0.5 

6.0 

Smallest 

size 

collected 

(§50% eff., \i 

10 

200 

Cyclones are lined with refractories or water-jacketed 

for processing of hot gases and are fabricated of alloy 

steels for processing of corrosive gases. 

Scrubbers are enclosures in which dust particles are 

agglomerated in small drops of water, which then flow from 

the vessel. In impingement-type scrubbers, agglomeration is 

accomplished by driving the dust-laden gas at high velocities onto flooded targets. Wet centrifugal separators pass 

the dust-laden air through a zone of high-velocity water 

droplets. Wet dynamic precipitators cause the dust to 

I.i 

4-28 
P.63 

impinge on wetted fan blades. A venturi scrubber accelerates the dust-laden air through a venturi throat, where it 

atomizes the water to form droplets. 

Scrubbers lose efficiency rapidly in collecting particles below 5 microns. Efficiency loss is proportional to 

the pressure drop or power consumption. The major scrubber 

variables are presented in Table 4-3. 

Scrubber 

type 

Impingement 

Centrifugal 

Dynamic 

Venturi 

Table 4-3. 

Water 

consumption 

per 

1,000 cfm 

gas, gpm 

3-5 

4-10 

1 

3-15 

SCRUBBER 

Pressure 

drop, 

in. 

6-8 

2-6 

1 

12-60 

VARIABLES 

Capacity, 

cfm 

90,000 

140,000 

25,000a 

140,000 

Max. 

efficiency, 

% (Particle 

size range) 

95 

(1-5 micron) 

90 

(2-5 micron) 

95a 

(2-5 micron) 

98 

(submicron) 

Estimated 

Scrubbers are used for control of thermal dryer emissions because they can accommodate gas temperatures up to 

250°F and are insensitive to the heavy moisture content. 

Orifice meters are commonly used for measuring the scrubber 

water flow rates. 

4-29 
£.64 

Table 4-4 presents the flow rate variables for six 

common orifice sizes. 

Pressure 

lb/in2 

20 

30 

40 

50 

60 

Table 4-4 

3/16 

3.0 

3.6 

4.1 

4.6 

5.1 

. ORIFICE FLOW 

Water flow, gpm 

diameter of orifice 

1/4 

5.2 

6.4 

7.4 

8.2 

9.0 

5/16 

8.1 

10.0 

11.5 

12.8 

14.0 

3/8 

11.7 

14.4 

16.5 

18.5 

20.2 

RATES 

, in. 

7/16 

15.8 

19.5 

22.4 

25.0 

27.5 

1/2 

20.1 

25.4 

29.4 

32.9 

36.0 

Baghouses or fabric filters are applicable for capture 

of fine particles of dust when the gases are at moderate 

temperatures, contain no sticky materials, and are nonexplosive. 

The dust-laden stream is passed through a finely woven 

or felted fabric on which a layer of dust serves as the 

filtering medium. As this dust layer thickens, the bag is 

"shaken" mechanically or by abrupt pressure changes to 

remove a portion of the filter cake. 

The filter is usually in the shape of a circular 

closed-end cylinder 5 to 12 inches in diameter and up to 30 

feet long. Smaller filters are used to control emissions 

from bin and silo openings. The size of a filter installation depends on the amount of air and dust to be filtered 

4-30 
P.65 

The ratio of air to filter cloth area depends on several 

variables; different services require different ratios or 

filtering velocities. The guidelines used for filtering of 

coal dusts are ratios of 6/1 for high dust loadings and 

elevated temperatures, progressing up to 8/1 for general 

dust loadings. Pressure differentials range from 2 to 10 

inches w.g. 

Fabrics are selected on a basis of chemical resistance, 

tensile strength, temperature resistance, weave, and electrostatic characteristics. Operating temperatures of some 

common fabrics are shown in Table 4-5. 

Cotton 

Wool 

Dacron 

Glass 

Nylon 

Orion 

Table 4-5. OPERATING TEMPERATURES 

Maximum operating temperature, °F 

Long term 

160 

200 

275 

500 

200 

240 

Short term 

200 

250 

300 

650 

250 

290 

The mechanisms for cleaning the bags include hand 

shaking, reverse air jets, mechanical rappers, and bag 

shakers. Since a bag is out of service while it is being 

cleaned, the installation must be designed to accommodate 

4-31 
P.66 

this loss of service. The bags are fastened at the top, 

with quick-release fastenings to permit easy bag replacement, and are suspended in the dusty environment. A vacuum 

is introduced in the bag, pulling the air through the fabric 

bag for release through the top, leaving the dust collected 

on the exterior of the bags. In some installations the 

dusty air flows through the interior of the bag. 

The baghouse containing the fabric filters may be 

square, rectangular, or circular and is constructed of 

metal. The vertical dimension exceeds the length of the 

bags, and the top or roof is flat. The open bottom is 

connected to a conical or pyramidal section, which receives 

the dust shaken from the bags for removal by an airlock 

feeder valve. The baghouse is self supporting, with suitable walkways for access. 

4-32 
P.67 

5.0 INSTRUMENTATION AND RECORDS 

Instrumentation for measurement of process parameters 

and methods of recording these measurements are important in 

controlling and predicting process emissions. The accuracy 

of predicting emissions can be directly related to the 

degree of sophistication of the instrumentation and recordkeeping at the plant. The instrument reading provides an 

instantaneous indication of operating conditions; detailed 

records will provide a basis for reviewing plant operations 

over an extended period. 

The flow of coal through the preparation equipment is a 

constant function of the amount of coal input at the feeder 

conveyor. Overloading of the feeder conveyor will result in 

overloading of the equipment following it. Most of the 

equipment incorporates an indicator showing instantaneously 

the load being processed. 

In older plants most equipment control is of the ON-OFF 

type. In case of overloading, a red light comes on and the 

equipment is automatically stopped. These ON-OFF lights do 

not indicate in advance a potential malfunction or overload 

and are not helpful for indication of emissions. 

5-1 
P.68 

The newer and larger plants generally incorporate a 

central control room with automated instrumentation showing 

the instantanous loading and other major parameters such as 

pressure drop and temperature of the gases. The monitoring 

records of required process parameters are also maintained 

in this central control room. 

When the instruments indicate abnormal operating 

conditions, the operator can take action to prevent possible 

major equipment malfunction or plant shutdown. The use of 

instrument readings for predicting plant emissions is 

discussed in Section 8.0. 

5.1 PROCESS INSTRUMENTATION 

Instrumentation in the coal preparation plant is 

relatively simple in comparison with instrumentation at 

other process industries. The instruments generally found 

on coal preparation equipment are described below: 

Conveyor 

The conveyors are driven by electric motors; the 

current drawn by the conveyor motors varies directly with 

the conveyor load. The ammeters located in the control room 

indicate the instantaneous current drawn by the conveyor 

motors. When excessive current is indicated, conveyor and 

equipment loading should be investigated. 

5-2 
P.69 

Some conveyors are also equipped with load meters. 

These meters indicate the percent of rated load carried by 

the conveyor at a particular instant. Ammeters and load 

meters give basically similar indications. 

Crushers 

The crusher load is directly proportional to the feed 

rate and feed sizes. The crusher is driven by an electric 

motor. The ammeter for the motor is generally located in 

the central control room. Indication of excessive current 

should be investigated to determine the cause. 

Screens 

In addition to the load-current ammeters, the screens 

may be equipped with pressure gauges indicating the pressure 

of water to the sprays. The various correct combinations of 

load current and spray pressure should be established during 

performance tests for reference during periodic inspections. 

The increase in load cbrrent would mean increased screen 

loading; this should be matched by increased spray water, 

which will be indicated by the pressure gauge. 

Air Tables 

In general, the new air table installations will be 

equipped with instruments to indicate the load current, 

pressure drop across the air table, and pressure drop across 

the control equipment. The load current is indicated by the 

5-3 
P.70 

ammeter; pressure drops are indicated by the pressure 

gauges. These instruments can be located in a central 

control room. The correct combinations of these parameters 

should be established during performance tests for future 

reference. 

An excessive pressure drop across the air table means 

a higher percentage of fine coal in the table feed. This 

will also result in an increased load on the control device. 

The pressure drop across the control device should be 

matched to meet the increased particulate loading. 

Thermal Dryers 

Thermal dryers are equipped with instruments to indicate the feed rate and exit gas temperature. The exit gas 

temperature is continuously recorded and monitored. In the 

case of thermal dryers with venturi scrubbers, scrubber 

water supply pressure and pressure loss in the venturi 

constriction are also continuously monitored. The monitoring 

aspects are discussed under records in Section 5.2. 

The thermal dryer feed rate indicates the quantitative 

loading; however, this may not be useful for predicting the 

emissions. Emissions from the thermal dryer would depend on 

the moisture and fine-coal percentage of the feed. 

5-4 
P.71 

5.2 RECORDS 

The NSPS require the continuous monitoring of the flue 

gas temperature at the exit of the thermal dryer, pressure 

of the water supply to the venturi scrubber, and pressure 

loss in the venturi constriction, A record of these parameters 

will be available at the plant for inspection. 

Other records, though not required under NSPS, showing 

the plant feed rates and equipment malfunction and shutdown 

should be inspected to determine the plant's emissions 

between inspections. 

i ii. 

5-5 
P.72 

\A 

6.0 START-UP, SHUTDOWN, AND MALFUNCTIONS 

Emissions that occur during normal plant start-ups and 

shutdowns are exempted by regulations. The following 

sections discuss the possible causes of extended emission 

upsets and precautionary measures for preventing them. The 

primary emission sources are the air table and the thermal 

dryer, and, in some cases of malfunction, their control 

devices. The secondary emission sources are more numerous, 

less susceptible to upset, and more easily corrected. These 

sources are screens, breakers, crushers, conveyor transfer 

points, storage bins, loading and unloading stations, and 

supporting equipment. 

In this section, a brief discussion of emisssion during 

plant start-up and shutdown is followed by analysis of 

malfunctions that can occur in regular plant operation. 

6.1 START-UP AND SHUTDOWN 

A normal interruption during a shift, such as that 

caused by car changes, lack of coal, or mechanical failure 

of equipment, usually does not cause an emission upset 

because the plant is kept running. The heat of the thermal 

dryer is regulated, and the other emission sources will 

6-1 
P.73 

receive no coal to create, dust. Upon resumption of coal 

flow, the first coal encounters normal conditions. 

In start-up at the beginning of a shift or after a long 

breakdown, the period of adjustment is short, lasting only 

until the flow of coal through the plant is complete. In 

the starting sequence, each unit (or several) is brought online at a time interval. The normal procedure, on automatic 

starting, would energize all water pumps, air compressors, 

and related dust control equipment before coal is received. 

The thermal dryer should be up to temperature, and all 

sprays should be operational. At a well-designed plant, 

this sequence is interlocked, without recourse to bypass. 

Some plants are built with selected interlocks; these 

arrangements permit utilization of only certain sections of 

the plant or operation around nonfunctional equipment. 

Manual controls to allow bypassing of interlocks are common. 

Improper use of bypass features is the most probable reason 

for an emission upset during start-up of a plant with interlocks. 

The shutdown procedure for some plants is automatically 

executed in the reverse of start-up, with some variations. 

This permits the plant to "empty" itself; more commonly, the 

"stop" sequence is timed to a shorter period than is- required for traverse of the process circuit. In either 

6-2 
P.74 

event, the dust control equipment should be timed to continue operation after the coal feed is stopped, for a 

period long enough to allow the equipment to run clean. 

The coal preparation incorporates an emergency "stop" 

button which halts all equipment instantly. This procedure 

entails no particular ill effects, since everything (including 

the thermal dryer) stops operating. However, if the incoming 

coal is near the capacity of the circuits and a buildup of 

dust has occurred in critical spots, a short emission upset 

may occur on start-up. 

6.2 CHANGES IN COAL FEED 

Analysis of the incoming coal may change sufficiently 

to create plant emission upsets. This is most likely to 

occur at a central preparation plant that processes coal 

from several mines and different coal seams. The second 

most vulnerable plant is one that serves a large mine 

producing from both conventional and continuous mining 

sections, the conventional type producing finer coal. 

Variable feed also can prevail at a plant receiving coal 

from a stripping operation with auger production. 

Blending the raw coal, either from multiple storage 

units or by proportioned acceptance, will reduce the impacts 

of variable feed. Multiple storage facilities, however, are 

rare and very expensive; proportional feed is difficult and 

6-3 

-J 
P.75 

'i 

less positive as a control. Use of a single raw coal 

storage silo can produce the same problem at intervals, as 

can changes in surface moisture content caused by different 

levels of spraying underground, wet mines, precipitation on 

open storage piles, and exposure during transport. 

In the discussions that follow, it is important to 

remember that malfunctions occurring at many points in the 

coal preparation circuit may be attributable, at least in 

part, to changes in coal feed. 

6.3 MALFUNCTION OF SUPPORT EQUIPMENT 

Malfunctions of supporting equipment, usually mechanical 

failure, can cause frequent or sustained interruptions of 

plant operations. The most usual are listed below. 

Breakdown of conveyor drives, crushers, chains, centrifuges, feeders, pumps, or screen cloths. 

Blockage in bins or release of veil-chains or plates 

into the coal flow. 

Failure of magnetic protective equipment, permitting 

introduction of large "tramp" iron into the feed. 

Electrical accidents, inadequate power source, or 

inadequate lightning protection. 

Poorly controlled spraying, producing variable moisture 

content (at dry cleaning plants). 

Damage of ROM conveyor belt from tramp iron, misalignment, or oversized rock. 

6-4 
_P,76 

6.4 MALFUNCTIONS IN SOURCES OF FUGITIVE DUST 

Malfunctions in dust-producing equipment are caused by 

overload, poor maintenance or design, electrical failure, 

accident, or improper operation. 

Air Table 

The air table is most adversely affected by a sharp 

change in size distribution of the incoming coal to include 

greater amounts of extreme fines. This shift permits overloading of the dust control equipment. Simple overloading 

of the air table, which produces a similar condition, is 

caused by malfunction of the proportioning feeder on the air 

table or by desire of the operator to increase production. 

Air seals on the table, if not properly maintained, will 

become serious sources of fugitive dust emissions. 

Thermal Dryer 

The thermal dryer, like the air table, is subject to 

particulate emission standards. 

Overheating of a thermal dryer may be caused by failure 

of a regulating valve (gas or oil fired) or other control 

and usually will produce an "upset" plume. The "internals" 

of dryers involve mechanical (sometimes moving) parts, which 

are subject to wear and damage. The refractory lining also 

is subject to wear and damage and is subject to scheduled 

replacement. 

6-5 
P.77 

The second section of a thermal dryer is a largediameter cyclone, used to extract the particulate matter 

larger than 300 M from the gas stream. This cyclone has no 

internal working parts, but the refractory lining is subject 

to wear. Volume of air, temperature, and pressure drop are 

the chief criteria for satisfactory or normal cyclone 

operation. Other causes of emissions are mechanical failure 

of the discharge feeder and wearing of seals. 

The last section of a thermal dryer is a scrubber, used 

to remove the fine portion of coal (300 M x 0) from the air 

stream. The scrubber may incorporate a bypass for emergency 

use, which may be partially open and permit particulate 

emission. The inspector should examine the bypass during 

each plant inspection and should also examine records of 

bypass use. 

The venturi scrubber is the type most commonly used. 

Its efficiency is a function of the volume, pressure drop, 

and temperature of the contaminated air and the volume and 

pressure of the scrubbing medium (water). Deviation from 

established norms can be checked by reference to records of 

previous plant inspections. 

The inspector should examine the seals at manholes and 

duct collars for tight fit and should check the device for 

removal of solids and spent scrubbing liquids to ensure that 

6-6 
P.78 

V ,/ 

it is not blocked partially open. With a "variable venturi" 

type scrubber, the inspector must be provided with a record 

of the "normal" setting. Water is introduced internally 

through a nozzle or sprays, which, if blocked or inoperative 

could affect a zone of the venturi adversely. 

The moisture separators and/or demisters of a scrubber 

installation may become blocked, or partially so, particularly if they include a screen. Particular attention 

should be given to "ball-bed", "packed tower," and "packed 

bed" types of scrubbers, which incorporate a supplemental 

internal feature that may become blocked or cause resistance 

to the flow of gas or liquid. 

Screens 

Fugitive dust emissions occur at the screens when fine 

coal is involved. The coal preparation plants generally use 

three types of screens: grizzly, shaker, and vibrating. 

Grizzly screens are used on ROM coal preceding a 

crusher or loading a belt conveyor. They usually are served 

by sprays but are sometimes enclosed. The doors, plates, 

and seals of the enclosure are highly subject to damage by 

pieces of metal or rock. Wet incoming material may cause 

plugging of the branch air duct from the enclosure to the 

dust collector, which should be sized to carry dust-laden 

air, at the minimum pressure available, at a velocity of not 

less than 4500 fpm. 

6-7 
P.79 

Shaker screens are used infrequently, rarely providing 

a separation less than 2 inches (usually much larger). A 

hooded enclosure may be found alongside the screen. Principal malfunctions involve plugging, short-circuiting, or 

improper sizing of the conveying ducts, damage to the hood, 

or improper placement of the hood. 

A vibrating screen is the most common separating device. 

Many screens are flooded with water and constitute no dust 

source. The "dry" screens usually make a separation at 1/4-

3/8-1/2 inch and create fugitive dust. Malfunctions involve 

loose seals, damaged enclosures, open access doors, and 

blocked or short-circuited air ducts. 

Crushers 

Crushers, an important source of fugitive dust, are 

protected by sprays or dust collectors. A sudden appearance 

of fugitive dust may be caused by blockage or short-circuiting of air ducts, broken enclosures or seals, or open 

access doors. If operation of the crusher is changed, an 

upset may occur. A hammermill will respond to higher speeds 

with finer product and/or greater capacity, creating a new 

situation for dust control. Introduction of a coal of soft 

consistency also can introduce new problems. 

Breakers are subject to the same types of malfunctions 

described for crushers, caused by broken, loose, or mis6-8 
P.80 

Vt 

placed enclosures, blocked or short-circuited air ducts, 

open access doors, and overloading. Similarly, change of 

perforated plates to reduce the sizing or introduction of 

coal from different seams can cause fugitive dust emissions. 

Conveyor Transfer Points 

Conveyor transfer points are sources of fugitive dust 

when dry coal containing the 3/8 x 0 inch increment is 

processed. If the material is larger than 3/8 inch or 

surface moisture content exceeds about 9 percent, dust 

emissions do not occur. The enclosure usually has an access 

door, which may be removed or left open, thus short-circuiting the "pickup" air. Rubber seals or curtains also may 

be removed or damaged. Airflow may be insufficient to 

gather the dust. The duct carrying the dust-laden air away 

may be blocked, broken, or poorly sized. A damper may be in 

the wrong position, or the chute leading from the conveyor 

pulley may be blocked, permitting spillage. The duct 

should carry the volume of air at a velocity of 4500 fpm. 

Proper conveying pressure may be unavailable because of 

malfunction or overloading of the collecting device at the 

duct terminal. Speeding or overloading of a conveyor may 

cause an emission upset at the terminal. Reference to 

earlier inspection reports will disclose any deviation from 

the normal flow of coal at a given point. Most of the 

6-9 
P.81 

malfunctions described above are readily handled by maintenance and replacement of damaged components. 

Storage Facilities 

Storage bins or silos include several possible fugitive 

dust sources. The feeder underneath a bin may be enclosed 

in a structure similar to that at a belt conveyor transfer 

point just described, and the same malfunctions may occur. 

Most storage bins and silos are covered and are loaded 

by the conveyor. The conveyor discharge has been discussed, 

but a supplemental bin exhaust should be present to equalize 

pressure inside against the volume of incoming coal. This 

port is sometimes equipped with a bin vent filter, which can 

become plugged because of infrequent filter changes or 

exposure to water. The bin may also have ducts leading from 

these vents to a central dust collector. The bin should be 

exhausted at an air volume rate equal to twice the volume of 

incoming coal. Emissions may occur if this amount of air is 

not provided or if the lines from the bin are inadequate, as 

discussed with respect to conveyors. 

A third possible emission source is present on a few 

silos, usually storing ROM, which have large openings 

through the walls near the top and around the circumference 

at spaced intervals. These openings may have doors, which 

are normally closed to contain the coal within the silo. 

6-10 
P.82 

Coal is released upon operator demand or when the silos 

become nearly full, flowing through the holes to open 

storage around the silo. This operation can produce substantial fugitive dust emissions. 

Loading and Unloading Stations 

The points at which outgoing coal is loaded and incoming coal is received constitute significant sources of 

fugitive dust emissions because of the large volumes of coal 

that are handled, often without adequate controls. The 

chutes, hoods, bins, and miscellaneous full or partial 

enclosures involved in unloading and loading operations are 

subject to the same malfunctions described earlier with 

respect to similar equipment elsewhere in the plant: 

passages are blocked or plugged, access doors are removed or 

left ajar, seals are broken or faulty, metal components are 

dented, corroded, or otherwise deteriorated. Essentially 

simple structures or devices may be inoperable because of 

damage that is undetected or ignored. The task of the 

inspector is to note and record all actual or possible 

points of dust emission requiring the attention of plant 

operators. Certain points of the coal transfer operations, 

however, are worthy of special note. 

Unloading from railroad cars may involve the use of 

retractable chutes, operated pneumatically, which often lose 

6-11 
P.83 

t i 

I ! 

I 

t 

precision because of wear or erratic power supply. Conventional loading of railroad cars is sometimes protected by 

oil spraying, the effectiveness of which may be deteriorated 

by broken or plugged sprays and lines, damaged pumps or 

tanks, erratic pressure control valves, and insufficient oil 

supply. Barge loading is by chute, retractable to a degree 

but still permitting free fall of the coal into the barges. 

In stockpile loading by conveyor, coal is discharged from a 

conveyor high in the air and falls either through retractable 

chutes or loading stacks. Loading stacks are hollow, 

stationary columns, either of steel or concrete, reaching 

from the ground to the belt conveyor discharge. They have 

staggered partial openings at different elevations, extending 

the entire length, to offer some protection from the wind 

and to permit accumulation of the stockpile around the 

exterior. If the closures are blocked in an open position, 

adverse air currents may be generated. 

In all of the loading operations, windbreaks are 

essential for control of air currents. These should be well 

placed with respect to prevailing winds, and must be well 

maintained for maximum effectiveness. 

The dust emission problems involved at stations for 

unloading of the ROM coal naturally are similar to those at 

loading points. 

6-12 
P.84 

-1 

Truck dump bins sometimes are partially enclosed. 

Sheeting may be absent from these enclosures, either deliberately or by accident. Many such bins have no dust control 

system. Any hooded dust control must allow for very high 

airflow because of the high rate at which the air in the bir 

is exhausted. 

Stations for unloading of railroad cars are normally 

housed, and the fugitive dust is controlled by sprays. 

Those with dust-collecting hoods are subject to the malfunctions described earlier. 

6.5 MALFUNCTION OF CONTROL DEVICES 

Malfunctions of control devices principally involve 

scrubbers, cyclones, sprays, baghouses, and dust collection 

systems. Scrubbers have been discussed in connection with 

thermal dryers. 

A cyclone should be installed to operate on predetermined volumes of particulate-bearing air at given temperature limits, with a minimum stipulated recovery of 

particles in the various size ranges. Recovery is determined by the shape of the cyclone and the volume flow 

through it. This is true of all cyclones, whether single or 

in clusters, large or small, hot or cold. 

Detecting the cause of a malfunction will involve 

isolating the circumstance that has changed since normal 

operation was recorded. 

6-13 
P.85 

Air volume can be measured at the outlet of the cyclone. It may be low if the fan is worn, belts are loose or 

broken, or intake area is no longer sufficient to pass 

adequate air at the pressure available. Blockage anywhere 

in the system is equally damaging. 

Temperature can be measured at the cyclone inlet. If 

it deviates from the design limits, the volume of air at a 

given pressure will be incorrect. Temperature variations of 

these proportions would probably reflect the introduction of 

heated air. 

Determining pressure drop "across the cyclone" requires 

pressure readings before and after the device. Common 

problems are a worn vacuum pump, loose belts, and an opening 

in the duct following the cyclone. If the pressure is 

constant at the fan, the pressure has increased downstream 

from the cyclone or an accident has occurred within the 

cyclone. 

The shape of the cyclone can be changed by large dents, 

fallout of the refractory liner, mechanical failure of the 

feeder discharging solids at the bottom, and by blockage due 

to accumulation of fire clay or wet fine coal on the interior walls. In a wet-wall cyclone, the flow of liquid 

down the interior walls may be inadequate to reach the 

bottom, causing buildup on the interior. In cyclone clusters, 

partial blockage of any of the several small units can 

6-14 
P.86 

reduce the flow of air. As with many of the processing 

components, a change in analysis of incoming coal can cause 

difficulty. 

Spray systems in a coal preparation plant can range 

from low-pressure "fish tails" or hollow-nozzle types to 

high-pressure (300 psi) impingement types. A wetting agent 

is occasionally used in the spray water. Appearance of 

excessive particulate probably may be traced to one of the 

following causes: 

0 Introduction of more than normal amounts of dust. 

° Misalignment, damage, or plugging of spray heads 

or header. 

° Damage of a control valve. 

° Plugging of a line filter or incoming line. 

° Wear or damage of pump or drive. 

° Lack of water. 

0 Damage of sensor device or on-off switch. 

° Accumulations of ice in lines or spray heads. 

The criteria for successful operation of fabric filters 

are pressure drop across the baghouse, temperature of the 

incoming air, and the volume of air per surface area of 

filter fabric. Other possible causes of fugitive dust 

emissions include the usual factors involving wear, damage, 

looseness, plugging, or other impediments to effective 

operation of fans, blowers, ducting, hoppers, and similar 

6-15 
P.87 

components. In addition, the inspector may check for the 

following: 

° New bags pass fine particulate until they become 

permeated and coated. If new fabric is used it 

may not be compatible with the air velocity, 

temperature, or pH count of the stream. 

0 Interior diaphragms may be punctured or loose. 

0 Cleaning cycles may remove too many bags from the 

circuit, leaving an inadequate number in operation. 

This is most likely to occur just before planned 

maintenance, when a number of bags are tied off. 

° The collecting hopper below the bags may be filled 

with dust. Foreign materials (bags, hose, tools) 

sometimes enter the hopper and cause blockage. 

0 Bag cleaning may be neglected in manual operation, 

or the rapping or shaking mechanisms may suffer 

mechanical failure; reverse air jet (pneumatic) 

systems or timing devices may fail or become 

plugged. 

° Bypassing devices may become damaged, partially or 

completely blocked, or out of cycle. 

Systems for collection of dust from various sources 

throughout the plant are made up of hoods and enclosures at 

emission points, with ducts leading to junctures and finally 

to a major duct to the collecting device, usually a baghouse. Each of the branch lines or ducts must be properly 

sized to maintain adequate flow. Air intakes or cleanouts 

located at critical points are equipped with dampers (valves), 

which can cause malfunction. Connection of branch lines to 

larger ones must not be sharp (45°, preferably 30°) and 

should enter from the top or sides, never opposing. Any 

6-16 
P.88 

h/ 

bend in the ducting should have an inside radius of 2 times 

the pipe diameter. Introduction of water into the duct 

collection system is another source of potential trouble. 

6-17 
P.89 

7.0 EMISSION PERFORMANCE TESTS 

The emission performance tests are intended to ser_'e as 

a basis for determining compliance status of the plant 

during later inspections. These initial performance tests, 

therefore, must be conducted under conditions that are 

representative of plant operation. Two factors are of 

paramount importance: the coal being cleaned and the 

equipment loadings during the test. Analysis of the coal 

processed in the test should be typical with respect to 

percentage of fines and moisture content. Similarly, 

equipment loadings, which usually will differ from the rated 

or design capacities, should represent the maximum continuous loading in plant operation. As discussed in the 

balance of this section, the inspector will work with plant 

officials and the emissions testing contractor in selection 

of process paramaters for the emissions test. 

7.1 PRETEST PROCEDURES 

Before details of the test procedure are established, 

the EPA inspector should discuss the test objectives with 

the persons involved. In providing background information 

for plant personnel, he will enhance their understanding of test 

7-1 
P.90 

procedures and thus establish a framework in which cooperative effort is likely. These pretest discussions will 

focus on three principal areas: the NSPS, the operating 

parameters, and the test schedule. 

NSPS Briefing 

The inspector should be prepared to explain the background of the New Source Performance Standards and their 

relationship to the overall EPA goals. He should give 

details of the procedures used by EPA in setting the standards and explain the units in which emissions are reported, 

as required by regulations. He will point out that the NSPS 

specifically require monitoring of thermal dryer temperature, 

water supply pressure to the venturi scrubber, and pressure 

loss in the venturi constriction. Although details of plant 

operation are highly variable, the inspector will find that 

detailed knowledge of coal cleaning processes and of EPA 

activities will enable him to answer questions effectively. 

Operating Parameters 

The effects of all the major process variables will 

determine selection of process parameters during the emission performance tests. The selected values should represent the higher extreme of emission levels encountered in 

plant operations. As mentioned earlier, the major process 

variables affecting emissions are coal analysis (fines and 

moisture) and feed rate. 

7-2 
/ 

\x i)jA 

P.91 

The percentage of fines in the feed entering a thermal 

dryer or air table will directly and proportionally affect 

the potential emissions through the equipment. Greater 

percentages of fine coal in the feed may result in larger 

amounts of particulate matter escaping through the control 

device to the atmosphere. For control of emissions to the 

level specified by the regulations, a higher pressure drop 

would be required across the scrubber. Therefore, the 

percentage of fines in the feed during a performance test 

should represent the higher extremes encountered in continuous plant operation. 

Moisture content of feed coal has a similar direct 

effect. Notice also, however, that higher moisture content 

of the feed will result in reduction of air table emissions 

and fugitive dust emissions. A higher moisture content of 

feed entering the thermal dryer may result in flue gases 

with higher moisture, causing potential difficulty in 

assessing compliance with opacity standards. 

The feed load (tonnage) during the performance test 

should be representative of the maximun continuous rate at 

which the plant is operated in overload conditions. This 

will ensure representative high loading of the process 

equipment during the test. 

7-3 
P.92 

'Ci 

Test Schedule 

The emission performance test schedule will be determined jointly by the inspector, the test contractor, and 

plant personnel. Plant personnel should provide information 

regarding the schedule and analysis of coal receipts, 

scheduled maintenance, operating schedules and similar 

operating factors. The inspector will discuss fully with 

plant personnel and the test contractor the methods and 

procedures of testing. Size of test crew will depend on the 

number of sampling points and total test duration. An 

experienced emission testing contractor will be able to make 

that judgment, with concurrence of the inspector and plant 

officials. 

Local weather conditions and forecasts should be 

considered as the testing time approaches. Significant 

rainfall or snowfall could limit the effectiveness and 

accuracy of emissions tests. 

It is of utmost importance that the inspector take 

proper safety measures to prevent mishaps during the plant 

inspections. He should always use personal protective equipment such as hard hat, safety glasses or goggles, ear plugs, 

safety belts, and safety shoes during the plant visit. 

Where the plant prescribes standard safety procedures for 

protection of staff and visiting personnel, he should adhere 

to these strictly during the inspections. 

7-4 
P.93 

KfS I: 

Table 7.1 outlines major planning responsibilities of 

the three groups involved in emission performance tests. 

7.2 TEST MONITORING 

It is important to remember that the initial emissions 

tests determine the reliability of later emission compliance 

inspections and tests. All persons involved in the emissions 

tests should seek to ensure that the tests are conducted 

fairly and the test results are valid. 

The inspector plays a major role in monitoring the test 

procedures and plant operating parameters during the test 

period. He must ensure that the tests are carried out 

according to standard procedures. 

The following are key factors to be monitored continuously during the tests: 

° Plant feed rate. 

° Percentage of fines and moisture content of the 

feed. 

° Air table feed rate and baghouse pressure. 

° Thermal dryer feed rate and exit gas temperature. 

° Durations and intervals of emissions tests. 

Table 7-2 presents a detailed inspection checklist to 

aid the inspector in performing his duties in a thorough and 

objective manner. 

At least three sets of process observations aire recommended. The number of stack test observations during 

7-5 
Table 7-1. EMISSION PERFORMANCE TEST RESPONSIBILITIES 

P.94 

Group/Person 

EPA Inspector 

Plant Personnel 

Test Contractor 

o 

o 

o 

o 

o 

o 

o 

o 

o 

0 

o 

o 

o 

o 

o 

Responsibilities 

Arrange pretest meeting; explain 

test goals and procedures. 

Review and approve test schedule 

prepared by test contractor. 

Check location of test points. 

Select test feed analysis and feed 

rate in consultation with plant 

personnel and request that major 

parameters be recorded. 

Observe "and follow normal safety procedures and those specified at the pla 

Provide information for inspector 

regarding types of coals cleaned 

and maximum feed rates. 

Provide work area for test contractor. 

Identify emission points. 

Identify and prepare ports. 

Provide details of stack sites and 

control equipment. 

Provide details of plant instrumentation. 

Provide equipment maintenance 

schedule; select test dates in 

consultation with inspector and 

test contractor. 

Present test schedule to equipment 

operators and supervisors. 

Familiarize test crew with 

test sites, methods, and NSPS 

requirements. 

Prepare test schedule; obtain 

approval from inspector and plant 

personnel. 

7-6 
r"i 

V 

P.95 

Table 7-2. CHECKLIST FOR PERFORMANCE TEST 

GENERAL INFORMATION 

Plant Name: 

Mine Name: 

Plant Address:. 

Contact at Plant: 

Date of Inspection:. 

Inspected by: 

Plant Rated Feed Capacity, ton/hr:. 

Plant Feed Rate, ton/hr: 

Year of Plant Commissioning/ 

Major Modification: 

Facility Data: Cleaning Techniques 

Number of Stacks: 

Wet 

Dry 

Other. 

(continued) 

7-7 
P.96 

Table 7-2 (continued) 

COAL DATA 

COAL SEAM: 

Size 

Surface moisture, % 

1/4x0, % 

Ash, % 

Strip mining, % 

Continuous mining, % 

Conventional mining, % 

Raw coal 

as received 

1 2 3 

. 

Refuse coal 

1 2 3 

(continued) 

7-8 
Table 7-2 (continued). 

EQUIPMENT CHECKLIST 

P.97 

WEIGHING DEVICE: 

• Available Q Not Available 

Type: 

Scale design capacity:. 

Size of coal weighed: 

Last date of calibration: 

• ROM 

• Other 

Prescribed calibration frequency:. 

• l/4 x 0 

Plant hourly feed 

1st hour 2nd hour 

rate during'inspection, ton/hr 

3rd hour 4th hour 5th hour 6th hour 

Average hourly feed rate, ton/hr: 

Maximum hourly feed rate, ton/hr: 

PRIMARY CRUSHER/CRUSHER ENCLOSURE 

Feed rate: 

Feed capacity 

Load current:. 

ton/hr 

ton/hr 

amperes 

Fugitive dust control: [~] Good • Poor 

Type:Qspray • Cyclone •Fab . Filter 

Opacity of Emission:3 % 

Use EPA Method 9 for all opacity readings 

(continued) 7-9 
P.98 

rf 

I- i 

• i I 

i'i I 

\\ I 

Table 7-2 (continued). 

SECONDARY CRUSHER 

Feed rate: 

Feed capacity:. 

Load current:_ 

ton/hr 

ton/hr 

Fugitive dust control: 

Type: | | Spray 

Opacity of Emission:. 

amperes 

I | Good | I Poor 

I I Cyclone I I Fab. Filter 

AIR TABLE 

(continued) 

Table No. 

Baghouse No. 

Baghouse AP, in. 

Load current, amperes 

Cyclone No. 

Cyclone AP, in. 

Stack gas opacity, % 

Gas flow rate, acfm 

Particulate loading, 

gr/dscf 

Opacity, % 

Feed rate, t/hr 

1 2 3 4 

• t7-10 
P.99 

A Table 7-2 (continued). 

SCREENS/ENCLOSURES 

Location 

Feed rate, ton/hr 

Moisture content, % 

Product sizes 

Fugitive dust controls: 

Type: Spray 

Cyclone 

Fab. Filter 

Opacity of emission, % 

Screen No. 

1 2 3 4 

THERMAL DRYER 

Type 

Dryer feed rate:. 

Dryer feed size: 

Feed moisture content: 

Product moisture content: 

Fan load current: 

Fan suction AP: 

Drying chamber AP 

.Btu Rating 

ton/hr 

.ton/hr 

.% 

% 

amperes 

in, vac. 

in, vac. 

Flue gas temperature at dryer exit: normal__ 

(for last 12 hrs. of continuous maximum 

normal operation) minimum 

Last date of temperature recorder 

calibration: = 

Cyclone outlet temperature:. 

Cyclone AP: in. 

(continued) 

_°F 

_°F 

7-11 

v 
P.100 

il 

Tabl e 7-2 (continued). 

FLUE GAS SCRUBBER 

Type: 

0 Water supply pressure (for 

last 12 hrs. of continuous 

normal operation) 

° Pressure loss at scrubber 

(for last 12 hrs. of continuous normal operation) 

Last date of recorder calibration: 

Prescribed frequency of calibration: 

Norma1_ 

Maximum. 

Minimum. 

Normal_ 

Maximum 

Minimum 

Opacity of flue gas at stack exit, % 

Particulate concentration at exit, gr/dscf:. 

.in, 

.in, 

in, 

.in. 

.in, 

.in. 

CONVEYOR/TRANSFER POINTS 

Draw a rough sketch of facility layout indicating and numbering the conveyors, using the graph paper on following page 

Use same numbers to identify the conveyors in the followinq 

table:

 y 

Location 

Receiving unit 

Discharge conveyor width, 

Discharge conveyor speed. 

Rated capacity, ton/hr 

Load current, amperes 

Type of dust control: 

spray 

cyclone 

fab. filter 

Water press, in. 

Water flow, gpm 

Opacity of emission, % 

in. 

ft/min. 

Conveyor No. 

1 2 3 4 

(continued) 7-12 

_j 
P.1 

Tabl e 7-2 (continued ) 

FACILITY LAYOUT 

(continu e 7-13 
Table 7-2 (continued). 

P3. 

LOADING STATION 

Type: I I Truck Railroad 1 I Barge 

Qunit Train L_J Other 

Feed capacity: 

Actual feed rate: 

Extent of dust control: 

Fan load Current: 

I ] Good 1 I Poor 

amperes 

ton/hr 

ton/hr 

Type of dust control: 

I Ispray: Water supply pressure in., flow gpm 

I I Cyclone: Pressure drop in., flow cfm 

LJ Fabric filter: Pressure drop. j.n. , flow cfm 

Condition of collector bags 

Emission opacity % 

UNLOADING STATION 

Type: I I Truck Barge | | Railroad 

Feed capacity: ton/hr 

Actual feed rate : ton/hr 

Type of Control device: 

1 ] Spray: Pressure drop in. , flow gpm 

in. , flow cfm 

Fabric filter: Pressure drop in., flow cfm 

I I Cyclone: Pressure drop 

Emission opacity 

(continued) 

Condition of collector bags 

% 

7-14 

Ut 
P.3 

7-2 (continued). 

COAL STORAGE 

Type: • silo • Fabricated Bin 

Location: 

Size of coal stored: _ 

Type of coal stored:__ 

Dust control device: 

I I Spray 

Water supply pressure 

I I Cyclone 

Pressure drop 

[ZI Fabric filter 

Pressure drop 

Fan load current 

Raw coal Washed coal 

.in'. , flow _gpm 

in., flow. 

in., flow 

amps. 

Condition of collector bags 

Storage design feed rate ton/hr 

Actual feed rate ton/hr 

cfm 

cfm 

(continued) 

7-15 
Table 7-2 (continued). 

FIELD OBSERVATION CHECKLIST 

P.4 

GENERAL/ADMINISTRATIVE 

PLANT NAME 

PLANT ADDRESS 

SOURCE TO BE TESTED 

PLANT CONTACT 

J)ATE. 

PHONE 

OBSERVERS AFFILIATION 

REVIEWED TEST PROTOCOL? COMMENTS, 

REVIEWED PRETEST MEETING NOTES?. COMMENTS 

i ; • 

REVIEWED CORRESPONDENCE? COMMENTS 

TEST TEAM COMPANY NAME 

SUPERVISOR'S NAME 

OTHER MEMBERS 

ADDRESS 

TITLE _ 

PHONE 

i:i|: 

r i 

ii 

(continued) 

7-16 

J 
P.5 

Table 7-2 (continued). 

GENERAL/SAMPLING SITE 

STACK/DUCT CROSS-SECTION DIMENSIONS EQUIVALENT DIAMETER. 

MATERIAL OF CONSTRUCTION CORRODED? LEAKS? 

INTERNAL APPEARANCE: CORRODED? CAKED PARTICULATE? THICKNESS 

INSULATION? THICKNESS LINING? THICKNESS 

NIPPLE? I.D. LENGTH FLUSH WITH INSIDE WALL? 

STRAIGHT RUN BEFORE PORTS DIAMETERS 

STRAIGHT RUN AFTER PORTS DIAMETERS 

PHOTOS TAKEN? OF WHAT 

DRAWING OF SAMPLING LOCATION: 

MINIMUM INFORMATION ON DRAWING: STACK/DUCT DIMENSIONS, LOCATION AND 

DESCRIPTION OF MAJOR DISTURBANCES AND ALL MINOR DISTURBANCES, TRANSMISSOMETERS, AND CROSS-SECTIONAL VIEW SHOWING DIMENSIONS AND PORT 

LOCATIONS. 

(continued) 

7-17 
Xl 

1:1 

i f! 

i l l • 

P.6 

Table 7-2 (continued) 

GENERAL/SAMPLING SYSTEM 

SAMPLING METHOD (e.g., EPA 5) 

SAMPLING TRAIN SCHEMATIC DRAWING: 

MODIFICATIONS TO STANDARD METHOD 

PUMP TYPE: FIBERVANE WITH IN-LINE OILER CARBON VANE DIAPHRAGM 

PROBE LINER MATERIAL HEATED? ENTIRE LENGTH? 

TYPE "S" PITOT TUBE? OTHER 

PITOT TUBE CONNECTED TO: INCLINED MANOMETER OR MAGNEHELIC GAUGE 

RANGE APPROX. SCALE LENGTH DIVISIONS 

METER BOX BRAND SAMPLE BOX BRAND 

RECENT CALIBRATION OF ORIFICE METER-DRY METER? PITOT TUBES? 

NOZZLES? THERMOMETERS OR THERMOCOUPLES? MAGNEHELIC GAUGES? 

NUMBER OF SAMPLING POINTS/TRAVERSE FROM FED. REG. NUMBER TO BE USED 

LENGTH OF SAMPLING TIME/POINT DESIRED^ TIME TO BE USED 

(continued) 

7-18 
P.7 

Table 7-2 (continued). 

SAMPLING (USE ONE SHEET FOR EACH RUN IF NECESSARY) RUN #_ 

PROBE-SAMPLE BOX MOVEMENT TECHNIQUE: 

IS NOZZLE SEALED WHEN PROBE IS IN STACK WITH PUMP TURNED OFF?. 

IS CARE TAKEN TO AVOID SCRAPING NIPPLE ON STACK WALL? 

IS AN EFFECTIVE SEAL MADE AROUND PROBE AT PORT OPENING? 

IS PROBE SEAL MADE WITHOUT DISTURBING FLOW INSIDE STACK?. 

IS PROBE MOVED TO EACH POINT AT THE PROPER TIME? 

IS PROBE MARKING SYSTEM ADEQUATE TO PROPERLY LOCATE EACH POINT? 

ARE NOZZLE AND PITOT TUBE KEPT PARALLEL TO. STACK WALL AT EACH POINT?. 

IF PROBE IS DISCONNECTED FROM FILTER HOLDER WITH PROBE IN THE STACK 

ON A NEGATIVE PRESSURE SOURCE, HOW IS PARTICULATE MATTER IN THE 

PROBE PREVENTED FROM BEING SUCKED BACK INTO THE STACK? 

IF FILTERS ARE CHANGED DURING A RUN, WAS ANY PARTICULATE LOST? 

METERBOX OPERATION: 

ARE DATA RECORDED IN A PERMANENT MANNER? ARE DATA SHEETS COMPLETE? 

AVERAGE TIME TO REACH ISOKINETIC RATE AT EACH POINT 

IS NOMOGRAPH SETTING CHANGED WHEN STACK TEMPERATURE CHANGES 

SIGNIFICANTLY? 

ARE VELOCITY PRESSURES (Ap) READ AND RECORDED ACCURATELY? 

IS LEAK TEST PERFORMED AT COMPLETION OF RUN? cfm @ IN Hg. 

PROBE, FILTER HOLDER, IMPINGERS SEALED ADEQUATELY AFTER TEST? , 

GENERAL COMMENT ON SAMPLING TECHNIQUES 

IF ORSAT ANALYSIS IS DONE, WAS IT: FROM STACK? FROM INTEGRATED BAG? 

WAS BAG SYSTEM LEAK TESTED? WAS ORSAT LEAK TESTED? CHECKED AGAINST AIR? 

IF DATA SHEETS CANNOT BE COPIED, RECORD: APPROXIMATE STACK TEMPERATURE °F 

NOZZLE DIA. IN. VOLUME METERED ACF 

LIST ALL Ap.READINGS 

7—IQ (continued) ' 7 
• V 

i ' 

; I 

:l ' 

P.8 

t 

Table 7-2 (continued). 

TRAIN ASSEMBLY/FINAL PREPARATIONS (USE ONE SHEET PER RUN IF NECESSARY) RUN §. 

FILTER HOLDER CLEAN BEFORE TEST? FILTER HOLDER ASSEMBLED CORRECTLY?. 

FILTER MEDIA TYPE FILTER CLEARLY IDENTIFIED? FILTER INTACT?. 

PROBE LINER CLEAN BEFORE TEST? NOZZLE CLEAN? NOZZLE UNDAMAGED?_ 

IMPINGERS CLEAN BEFORE TEST? IMPINGERS CHARGED CORRECTLY? 

BALL JOINTS OR SCREW JOINTS? GREASE USED? KIND OF GREASE 

PITOT TUBE TIP UNDAMAGED? PITOT LINES CHECKED FOR LEAKS? PLUGGING?. 

METER BOX LEVELED? PITOT MANOMETER ZEROED? ORIFICE MANOMETER ZEROED?. 

PROBE MARKINGS CORRECT? PROBE HOT ALONG ENTIRE LENGTH? 

FILTER COMPARTMENT HOT? TEMPERATURE INFORMATION AVAILABLE?. 

IMPINGERS ICED DOWN? THERMOMETER READING PROPERLY?. 

BAROMETRIC PRESSURE MEASURED? IF NOT, WHAT IS SOURCE OF DATA?. 

AH@ FROM MOST RECENT CALIBRATION AH@ FROM CHECK AGAINST DRY GAS METER 

NOMOGRAPH CHECK: 

IF AH@ = 1.80, TM = 100° F, % Hrfl = 10%, Ps/Pm = 1.00, C = (0.95) 

IF C^= 0.95, TS = 200° F, DN = 0.375. Ap REFERENCE = (0.118) 

ALIGN Ap = 1.0 WITH AH = 10; 0 Ap = 0.01, AH = (0.1) 

FOR NOMOGRAPH SET-UP: 

ESTIMATED METER TEMPERATURE °F ESTIMATED VALUE OF Ps/Pm. 

ESTIMATED MOISTURE CONTENT % HOW ESTIMATED? 

C FACTOR ESTIMATED STACK TEMPERATURE _°F DESIRED NOZZLE DIAMETER 

STACK THERMOMETER CHECKED AGAINST AMBIENT TEMPERATURE? 

LEAK TEST PERFORMED BEFORE START IF SAMPLING? RATE CFM @ IN. Hg. 

(continued) 

7-20 
P.9 

n 

Table 7-2 (continued). 

SAMPLE RECOVERY 

GENERAL ENVIRONMENT-CLEANUP AREA 

WASH BOTTLES CLEAN? BRUSHES CLEAN? BRUSHES RUSTY?. 

JARS CLEAN? ACETONE GRADE RESIDUE ON EVAP. SPEC. 

FILTER HANDLED OK? _PROBE HANDLED OK? IMPINGERS HANDLED OK?. 

AFTER CLEANUP: FILTER HOLDER CLEAN? PROBE LINER CLEAN? 

NOZZLE CLEAN? IMPINGERS CLEAN? BLANKS TAKEN? 

DESCRIPTION OF COLLECTED PARTICULATE 

SILICA GEL ALL PINK? RUN 1 RUN 2 RUN 3 

JARS ADEQUATELY LABELED? JARS SEALED TIGHTLY? 

LIQUID LEVEL MARKED ON JARS? JARS LOCKED UP? 

GENERAL COMMENTS ON ENTIRE SAMPLING PROJECT: 

(continued! 

7-21 
P.10 

I ; •• > 

,1 

Table.7-2 (continued). 

SAMPLE TRANSPORT PARTICULATE CHECK LIST 

Samples are to be the direct responsibility of 

a senior member of the source test team until the 

responsibility is transferred to the laboratory 

j | supervisor. 

All liquid samples must be airtight, the liquid 

level marked, then stored properly upright to prevent 

spillage or breakage. 

All solid samples are to be sealed and stored to 

prevent the loss of samples or contamination from 

the ambient sources. 

All sample containers must be properly marked on 

outside to avoid rough handling during transport 

of the sample to the laboratory. 

All sample containers locked to insure the sample 

integrity during transport. 

The sample log (chain of custody) is initiated 

during sample recovery to insure quality assurance 

from the moment of collection. 

i 

i i 

x 

1 (continued) 

v i ', 

i 

I'ix 

fli 

7-22 
P.11 

Table 7-2 (continued). 

ANALYTICAL PARTICULATE CHECK LIST 

Analytical balance should be calibrated with Class 

S weights at the time of use. 

Desiccator contains anhydrous calcium sulfate. 

Filter and any loose particles from the sample 

container desiccated from 24 to 96 hours to a 

"constant weight" means a difference of no more 

than 0.5 mg or 1 percent of total weight less tare 

weight, whichever is greater, between consecutive 

weighings, with no less than 6 hours of desiccation time between weighings and no more than 2 

minutes exposure to the laboratory atmosphere 

(must be less than 50% relative humidity) during 

weighing. 

Record level*of liquid in containers on analytical 

data sheet to determine if leakage occurred during 

transport. 

Blank filters desiccated to a constant weight. 

Blank weight should not vary from original weight 

by more than + 1.0 mg. 

Liquid in sample containers remeasured by the 

analyst either volumetrically to + 1 ml or gravimetrically to + 0.5 g. 

Acetone-rinse samples evaporate to dryness at 

ambient temperature and pressure in a tared 250-ml 

beaker. Prevent dust or objects from entering the 

beaker by placing a watch glass over the beaker 

during evaporation. 

The dried sample was desiccated to a constant 

weight and reported to the nearest 0.1 mg. 

The acetone blank was analyzed simultaneously with 

the acetone rinse using the same procedures. 

(continued) 

7-23 
P.12 

Table 7-2 (continued). 

Silic a gel was weighed to the nearest 0.5 g using 

a balance in the field or laboratory. 

Sample beakers covered with parafilm and stored 

along with used filters until report is accepted by 

control agency or unti l such time as specified by 

the agency. 

WAS THE TEST TEAM SUPERVISOR GIVEN THE OPPORTUNITY TO READ OVER THIS CHECKLIST? 

DID HE DO SO?. 

OBSERVER'S NAME, .TITLE, 

AFFILIATION. SIGNATURE 

7-24 
P.13 

n 

emission performance tests will depend on the mutual agreement of the inspector, plant operators, and test contractor; 

for each set of stack test data, corresponding process data 

should be recorded. A separate copy of the checklist for 

each set of observations will facilitate the comparison of 

observations. 

Note that NSPS regulations specify particulate concentrations only for thermal dryers and air tables; all 

other equipment is governed by opacity regulations. The 

values observed during the test should fall within the 

limits prescribed by the regulations. If they do not, plant 

officials should be notified so that they may take the 

necessary corrective action. The inspector should then 

schedule another test in accordance with agency policy. 

7-25 
P.M 

8.0 PERIODIC COMPLIANCE INSPECTIONS 

Periodic inspections following the emissions performance tests will enable the inspector to determine the 

current compliance status of the plant. The inspection 

mainly involves comparison of current plant operations with 

those recorded during the emissions tests. The plant 

instrumentation and records constitute the major information 

source for the inspector. In addition, he will use the 

emissions test checklist for periodic inspection, presented 

as Table 8-1. 

8.1 PERFORMING THE PERIODIC INSPECTION 

The periodic inspection generally involves the following steps: 

° Obtain schedule of plant operations during the 

proposed inspection period. 

° Study all available plant data including details 

of the performance tests, emission points, and 

control equipment. 

° Study instrumentation data gathered in performance 

tests. 

° Note unusual characteristics of the plant, and 

comments made by previous inspectors. 

° Inform plant officials of the proposed inspection 

and ensure that records are current and available 

for inspection. 

r 
P.15 

Table 8-1. CHECKLIST FOR PERIODIC INSPECTION 

GENERAL INFORMATION 

Plant Name:. 

Mine Name: 

Plant Address: 

Contact at Plant 

Date of Inspection: 

Inspected by: 

Plant Rated Feed Capacity, ton/hr:. 

Plant Feed Rate, ton/hr: 

Year of Plant Commissioning/ 

Major Modification: 

Facility Data: Cleaning Techniques 

Number of Stacks: 

H

Wet 

Dry 

• Other. 

(continued) 

8-2 
P.16 

Table 8-1 (continued) 

COAL DATA 

COAL SEAM: 

Size 

Surface moisture, % 

1/4x0, % 

Ash, % 

Strip mining, % 

Continuous mining, % 

Conventional mining, % 

Raw coal 

as received 

1 2 3 

Refuse coal 

1 2 3 

(continued) 

8-3 
P.17 

Table 8-1 (continued). 

EQUIPMENT CHECKLIST 

WEIGHING DEVICE: 

• Available • Not Available 

Type: 

Scale design capacity: 

Size of coal weighed: • ROM 

• Other. 

• l/4 x 0 

Last date of calibration: 

Prescribed calibration frequency:. 

Plant hourly feed 

1st hour 2nd hour 

rate during inspection, ton/hr 

3rd hour 4th hour 5th hour 6th hour 

Average hourly feed rate, ton/hr: 

Maximum hourly feed rate, ton/hr: 

PRIMARY CRUSHER/CRUSHER ENCLOSURE: 

Feed rate: 

Feed capacity: 

Load current: 

ton/hr 

ton/hr 

amperes 

Fugitive dust control: •Good . • Poor 

Type:Qspray • Cyclone •Fab . Filter 

Opacity of Emission:3 % 

Use EPA Method 9 for all opacity readings. 

(continued) 

8-4 
ft 

P.18 

Table 8-1 (continued) 

SECONDARY CRUSHER 

Feed rate: 

Feed capacity:. 

Load current: 

ton/hr 

ton/hr 

amperes 

I I Goo d I | 

• 

Fugitive dust control: Poor 

Type: I | Spray Cyclone Fab. Filter 

Opacity of Emission: % 

AIR TABLE 

Table No. 

Baghouse No. 

Baghouse AP, in. 

Load current, amperes 

Cyclone No. 

Cyclone AP, in. 

Stack gas opacity, % 

Gas flow rate, acfm 

Particulate loading, 

gr/dscf 

Opacity, % 

Feed rate, t/hr 

(continued' 

8-5 
P.19 

Table 8-1 (continued). 

SCREENS/ENCLOSURES 

Location 

Feed rate, ton/hr 

Moisture content, % 

Product sizes 

Fugitive dust controls: 

Type: Spray 

Cyclone 

Fab. Filter 

Opacity of emission, % 

Screen No. 

1 2 3 4 

THERMAL DRYER 

1 ;• 

\ 

Type 

Dryer feed rate:. 

Dryer feed size: 

Feed moisture content: 

Product moisture content: 

Fan load current: 

Fan suction AP: 

Drying chamber AP: 

Btu Rating 

ton/hr 

.ton/hr 

Flue gas temperature at dryer exit: normal 

(for last 12 hrs. of continuous 

normal operation) 

Last date of temperature recorder 

calibration: 

amperes 

in, vac. 

in, vac. 

normal 

maximum 

minimum 

oF 

op 

op 

Cyclone outlet temperature:. 

Cyclone AP: 

_°F 

in. 

(continued) 

3-6 
Table 8-1 (continued 

FLUE GAS SCRUBBER 

Type: 

P.20 

° Water supply pressure (for 

last 12 hrs. of continuous 

normal operation) 

0 Pressure loss at scrubber 

(for last 12 hrs. of continuous normal operation) 

Last date of recorder calibration: 

Prescribed frequency of calibration: 

0 Opacity of flue gas at stack exit, % 

Particulate concentration at exit, gr/dscf: 

n: 

it, 

qr/ 

Normal 

Maximum 

Minimum 

Normal 

Maximum 

Minimum 

% 

'dscf: 

i n. 

i n . 

i n . 

i n . 

in. 

i n. 

CONVEYOR/TRANSFER POINTS 

Draw a rough sketch of facility layout indicating and numbering the conveyors, using the graph paper on following page 

Use same numbers to identify the conveyors in the followinq 

table: 

Location 

Receiving unit 

Discharge conveyor width, in. 

Discharge conveyor speed, ft/min. 

Rated capacity, ton/hr 

Load current, amperes 

Type of dust control: 

spray 

cyclone 

fab. filter 

Water press, in. 

Water flow, gpm 

Opacity of emission, % 

Conveyor No. 

1 2 3 4 

(continued) 8-7 
Table 8-1 (continued). 

P.21 

- r • — » 

t

 •-.. , 

: • . 

. . ... 

„*.._. . 

! I 

T T 

J .. • . i 

_.l 

I'-

. l - • 

-~I—-•' .t J.. . 

I • <• 

- * -•... . 

iI 

,_.. 

.- - . ,- -JI.- . , I . i 

; i 

i * ! 

! I 

• - - 1 • I 1 

...I 

1 . I 

(continued) 

8-8 

_J 
P.22 

Table 8-1 (continued). 

LOADING STATION 

Type : I I Truck I I Railroad I I Barge 

LJunit Train LJ Other 

Feed capacity 

Actual feed rate: 

ton/hr 

ton/hr 

Extent of dust control: 

Fan load Current: 

[_] Good [_] Poor 

amperes 

Type of dust control: 

I | Spray : Water supply pressure in., flow gpm 

I I Cyclone: Pressure drop in., flow_ cfm 

I | Fabric filter : Pressure drop in. , flow cfm 

Condition of collector bags 

Emission opacity % 

UNLOADING STATION 

Type: I I Truck I | Barge I I Railroad 

Feed capacity: ton/hr 

Actual feed rate: ton/hr 

Type of Control device: 

I | Spray: Pressure drop. 

I | Cyclone: Pressure drop 

Fabric filter: Pressure drop. 

in. , flow gpm 

in. , flow cfm 

in. , flow cfm 

Emission opacity 

Condition of collector bags 

% 

(continued) 

8-9 
P.23 

Table 8-1 (continued). 

COAL STORAGE 

Type Osilo 

Location: 

• Fabricated Bin 

Size of coal stored: _ 

Type of coal stored:_ 

Dust control device: 

I I Spray 

Water supply pressure 

I I Cyclone 

Pressure drop 

I I Fabric filter 

Pressure drop 

Raw coal Washed coal 

.in. , flow _gpm 

Fan load current 

in., flow. 

in., flow 

amps. 

Condition of collector bags 

Storage design feed rate ton/hr 

Actual feed rate ton/hr 

(continued) 

cfm 

cfm 

8-10 ' 'vi 

J 
P2A_ 

u 

Table 8-1 (continued) 

ADDITIONAL CHECKS DURING PERIODIC INSPECTION 

RECORDS 

Weigh feeders 

Scrubber water supply 

Pressure loss at scrubber 

Dryer exit gas temperature 

Satisfactory Unsatisfactory 

• • 

• • 

• D 

COMMENTS ON OPERATION OF PLANT EQUIPMENT BETWEEN 

THE INSPECTIONS 

3-11 
P.25 

\ 

The frequency of inspections is governed by agency 

policy. A quarterly inspection is recommended unless complaints dictate more frequent inspections. 

Duration of the inspection will depend on the plant 

layout and number of emission sources; usually, however, 

each plant inspection requires 6 to 8 hours. Three sets of 

observations are recommended for each inspection. 

Major emphasis of the inspection is on checking facility records and observing the operation of process and 

control equipment, including instrumentation. The following 

procedures should be performed in the order shown whenever 

possible. The suggested format enables the inspector to 

tour the plant, observe the process, and monitor the instruments during operation. 

Observations Outside the Plant 

° Note plume opacity. 

° Check whether weighing devices are properly 

operating. 

Observations Inside the Plant 

° Use periodic inspection checklist (Table 8-1) for 

recording process parameters and control equipment 

data. 

0 Plant records of thermal dryer exit temperature, 

water supply to the scrubber, and pressure loss in the 

scrubber provide information on operations during 

the period between inspections. The inspector 

should be satisfied that the records are accurate 

and should not hesitate to ask for further information. 

s 

8-12 
P.26 

8.2 DETERMINING COMPLIANCE STATUS 

Compliance status of the plant is determined chiefly by 

comparing the inspection observations with those obtained 

during performance tests and previous inspections. Although 

such comparisons do not allow the prediction of quantitative 

emission rates, they do serve to indicate any emission 

upsets. Understanding the significance of each item in the 

checklist allows the inspector to weigh the effects of each 

item on process emissions. The relationships of checklist 

items with process emissions are discussed below. 

Coal Data 

The coal moisture content and percentage of fine coal 

(-1/4 in.) determine the loadings of the thermal dryer and 

air tables. Higher percentages of fine coal in the feed 

tend to increase thermal dryer emissions. Higher moisture 

content also increases the thermal dryer loading. If the 

feed analysis differs significantly from those recorded 

earlier, further investigation should be made. 

Feed Rate 

In general, the feed rates during periodic inspections 

should not be higher than those observed during performance 

tests. An increase in feed rate increases the loading of 

processing equipment. Normal feed variations up to 10 

percent may not significantly affect the emissions. An 

8-13 
P.27 

I 

U 

increase in feed rates should be compensated for by 

additional controls, such as higher flow rates for sprays 

and higher pressure drop across the venturi. Any increase 

in feed rates higher than 10 percent should be questioned. 

Load Current 

The preparation equipment generally includes ammeters 

that indicate the load current. Load current values should 

be compared with those observed during performance tests. 

Overloading of equipment will be indicated by the increase 

in demand of load current. 

Fugitive Dust Opacity 

NSPS regulations specify the opacity limits for fugitive dust emissions. Opacity readings according to Method 9 

should be taken to determine the fugitive dust emission 

compliance. 

Compliance Action 

If values observed in a periodic compliance test 

indicate that a citation is warranted, the inspector must 

clearly state to plant officials the grounds for such a 

citation. An on-site citation is justified only by clearcut violations, such as excessive opacity or failure of the 

plant to maintain or provide required records. 

8-14 
P.28 

REFERENCES 

'X.,, Leonard, J.W. , and D.R. Mitchell (eds.). Coal Preparation. Third Edition. New York. Society of Mining 

Engineers of AIME. 1968. 

2. Background Information for Standards of Performance: 

Coal Preparation Plants, Volume 1: Proposed Standards. 

U.S. Environmental Protection Agency, Research Triangle 

Park, N.C. EPA-450/2-74-021a. October 1974. 

3. Casey, J. Compilation of Technical Information on the 

Coal Preparation Industry. U.S. Environmental Protection Agency. Research Triangle Park, N.C. (unpublished) 

4. Background Information for Standards of Performance: 

Coal Preparation Plants, Volume 2: Test Data Summary. 

U.S. Environmental Protection Agency. Research Triangle 

Park, N.C. EPA-450/2-74-0216. October 1974. 

5. Air Pollutant Emission Factors Supplement (TRW Systems 

Group) for U.S. Environmental Protection Agency. 

Research Triangle Park, N.C. Contract No. CPA 22-69-

119. August 1970. 

6. Compilation of Air Pollution Emission Factors. Second 

Edition. U.S. Environmental Protection Agency. 

Research Triangle Park, N.C. AP-42. April 1973. 

7. Soderberg, H.E. Environmental, Energy, and Economic 

Considerations in Particulate Control. Mining Congress 

Journal 24-29, December 1974. 

8. Technical Guide for Review and Evaluation of Compliance 

Schedules for Air Pollution Sources. PEDCo-Environmental 

Specialists, Inc. for U.S. Environmental Protection 

Agency. Research Triangle Park, N.C. EPA Contract No. 

68-02-0607. July 1973. 

8-15 
P.29 

APPENDIX A 

NEW SOURCE PERFORMANCE STANDARDS 

COAL PREPARATION PLANTS 

A-l 
P.30 

2232 RULE

S AND REGULATIONS 

[FRL 462-7] 

PART 60—STANDARDS OF PERFORM-

ANCE FOR NEW STATIONARY SOURCES 

Coal Preparation Plants 

On October 24, 1974 (39 FR 37922). 

under secUon 111 ol the Clean Air Act, 

as amended, the Environmental Protec-

tion Agency (EPA) proposed standards 

ol perfonnance for new and modified 

coal preparation plants. Interested par-

ties were afforded an opportunity to par-

ticipate ln the rulemaking by submitting 

written comments. Twenty-seven com-

ment letters were received; six from coal 

companies, four from Federal agencies, 

four from steel companies, four from 

electric utility companies, three from 

State and local agencies, three from coal 

Industry associations and three from 

other Interested parties. 

Copies of the comment letters and a 

supplemental volume of background In-

formation which contains a summary 

of the comments with EPA's responses 

are available for public inspection and 

copying at the U.S. Environmental Pro-

tection Agency, Public Infonnation Reference Unit, Room 2922, 401 M Street, 

S.W.. Washington, D.C. 20460. In addi-

tion, the supplemental volume of back-

ground information which contains cop-

ies of the comment summary with EPA's 

responses may be obtained upon written 

request from the EPA Public Informa-

tion Center (PM-215), 401 M Street 

aw., Washington, D.C. 20460 (specify 

Background Information for Standards 

of Performance: Coal Preparation 

Plants, Volume 3: Supplemental Infor-

mation) . The comments have been care-

fully considered, and where determined 

by the Administrator to be appropriate, 

changes have been made to the proposed 

regulations and are incorporated in the 

regulations promulgated herein. 

The bases for the proposed standards 

are presented ln "Background Informa-

tion for Standards of Performance: Coal 

Preparation Plants" (EPA 450/2-74-02la, 

b). Copies of this document are avaUable 

on request from the Emission Standards 

Protection Agency. Research Triangle 

and Engineering Division, Environmental 

Park, North Carolina 27711, Attention: 

Mr. Don R. Goodwin. 

Summary of Regulation. The promul-

gated standards of performance regulate 

particulate matter emissions from coal 

preparation and handling facilities proc-

essing more than 200 tons/day of bitu-

minous coal (regardless of their location) 

as follows: (1) emissions from thermal 

dryers may not exceed 0.070 g/dscm 

(0.031 gr/dscf) and 20% opacity, (2) 

emissions from pneumatic coal cleaning 

equipment may not exceed 0.^40 g/dscm 

(0.018 gr/ dscf) and 10% opacity, and 

(3) emissions from coal handling and 

storage equipment (processing non-

bituminous as well as bituminous coal) 

may not exceed 20% opactity. 

Significant Comments and Revisions to 

the Proposed Regulations. Many of the 

comment letters received by EPA con-

tained multiple comments. These are 

summarized as foUows with discussions of 

any significant differences between the 

proposed and promulgated regulations. 

1. Applicability.—Comments were re-

ceived noting that the proposed stand-

ards would apply to any coal handling 

operation regardless of size and would 

require even small tipple operations and 

domestic coal distributors to comply with 

the proposed standards for fugitive 

emissions. In addition, underground 

mining activities may have been inad-

vertently Included under the proposed 

standards. EPA did not intend to regu-

late either these small sources or under-

ground mining activities. Only sources 

which break, crush, screen, clean, or dry 

large amounts of coal were intended to be 

covered. Sources which handle large 

amounts of coal would Include coal han-

dling operations at sources such as barge 

loading facUities, power plants, coke 

ovens, etc. as weU as plants that pri-

marily clean and/or dry coal. EPA con-

cluded that sources not Intended to be 

covered by the regulation handle less 

than 200 tons/day; therefore, the regu-

lation promulgated herein exempts such 

sources. 

Comments were received questioning 

the application of the standards to 

facilities processing nonbttumlnous coals 

(including lignite). As was stated ln the 

preamble to the proposed regulation, it 

Is intended for the standards to have 

broad applicability when appropriate. At 

the time the regulation was proposed, 

EPA considered the parameters relating 

to the control of emissions from thermal 

FEDERAL REGISTER, VOL. 41, NO. \0—THURSDAY, JANUARY 15, 1976 

A-2 

X 
_P.3i 

dryers to be sufficiently similar, whether 

bituminous or nonbltuminous coal was 

being dried. Since the time of proposal, 

EPA has reconsidered the application of 

standards to the thermal drying of nonbituminous coal. It has concluded that 

such application is not prudent ln the 

absence of speciflc data demonstrating 

the similarity of the drying characteristics and emission control characteristics to those of bituminous coal. There 

are currently very few thermal dryers or 

pneumatic air cleaners processing nonbituminous fuels. The facilities tested 

by EPA to demonstrate control equipment representative of best control technology were processing bituminous coal. 

Since the majority of the EPA test data 

and other Information used to develop 

the standards are based upon bituminous 

coal processing, the particulate matter 

standards for thermal dryers and pneumatic coal cleaning equipment have been 

revised to apply only to those facilities 

processing bituminous coal. 

The opacity standard for control of 

fugitive emissions is applicable to nonbituminous as well as bituminous coal 

since nonbltuminous processing facilities wiU utUize similar equipment for 

transporting, screening, storing, and 

loading coal, and the control techniques 

applicable for minimizing fugitive particulate matter emissions wiU be the 

same regardless of the type of coal processed. Typically enclosures with some 

type of low energy collectors are utilized. 

The opacity of emissions can also be reduced by effectively covering or sealing 

the process from the atmosphere so that 

arty avenues for escaping emissions are 

small. By minimizing the number and 

the dimensions of the openings through 

which fugitive emissions can escape, the 

opacity and the total mass rate of emissions can be reduced independently of 

the air pollution control devices. Also, 

water sprays have been demonstrated to 

be very effective for suppressing fugitive 

emissions and can be used to control even 

the most difficult fugitive emission problems. Therefore, the control of fugitive 

emissions at all facilities will be required 

since there are several control techniques 

that can be applied regardless of the 

type of coal processed. 

2. Thermal dryer standard.—One commentator presented data and calculations which Indicated that because of the 

large amount of fine particles in the coal 

his company processes, compliance with 

the proposed standard would require the 

application of a venturi scrubber with 

a pressure drop of 50 to 52 inches of water 

gage. The proposed standard waa based 

on the application pf a venturi scrubber 

with a pressure drop of 25 to 35 Inches. 

EPA thoroughly evaluated this comment 

and concluded that the commentator's 

calculations and extrapolations could 

have represented the actual situation. 

Rather than revise the standard on the 

basis of the commentator's estimates, 

EPA decided to perform emission tests at 

a plant which processes the coal under 

question. The plant tested ls controlled 

with a venturi scrubber and was operated 

at a pressure drop of 29 Inches during 

RULES AND REGULATIONS 

the emission tests. These tests showed 

emissions of 0.080 to 0.134 g/dscm (O.035 

to 0.058 gr/dscf). These results are 

numerically greater than the ^proposed 

standard; however, calculations Indicate 

that If the pressure drop were increased 

from 29 inches to 41 inches, the propoSed 

standard would be achieved, Supplemental Information regarding estimates of 

emission control needed to achieve the 

mass standard Is contained ln Section II, 

Volume 3 of the supplemental background information document. 

Since the cost analysis of the proposed 

standard was based on a venturi scrubber 

operating at 25 to 35 inches.venturi pressure loss, the costs of operating at higher 

pressure losses were evaluated. These results Indicated that the added cost of 

controlling pclhitants to the level of the 

proposed standard Is only 14 cents per 

ton of plant product even lf a 50 Inch 

pressure loss were used, and only Ave 

cents per ton in excess of the average 

control level required by state regulations 

in the major coal producing states. In 

comparison to the $18.95, per ton delivered price of U.S. coal In 1974 and even 

higher prices today, a maximum five 

cents per ton economic Impact attributable to these regulations appears almost 

negligible. The total Impact of 14 cents 

per ton for controlling particulate matter 

emissions can easily be passed along to 

the customer since the demand for 

thermal drying due to freight Tate savings, the elimination of handling problems due to freezing, and the needs of 

the customer's process (coke ovens must 

control bulk density and power plants 

must control plugging of pulverizers) will 

remain unaffected by these regulations. 

Therefore, the economic Impact of the 

standard upon thermal drying will not 

be large and the inflationary impact of 

the standard on the price of coal will be 

insignificant (one percent or less). From 

the standpoint of energy consumption, 

the power requirements of the air pollution control equipment are exponentially 

related to the control level such that a 

level of diminishing return is reached. 

Because the highest pressure loss that 

has been demonstrated by operation of 

a venturi scrubber on a coal dryer is 

41 inches water gage, which Is also the 

pressure loss estimated by a scrubber 

vendor to be needed to achieve the 70 

mg/dscm standard, and because energy 

consumption Increases dramatically at 

lower control levels (<70 mg/dscm), a 

particulate matter standard lower than 

70 mg/dscm was not selected. At the 70 

mg/dscm control level, the trade-off between control of emissions at the thermal 

dryer versus the Increase ln emissions at 

the power plant supplying the energy ls 

favorable even though the mass quantity 

of all air pollutants emitted by the power 

plant (SO>. NO., and particulate matter) 

are compared only to the reduction In 

thermal dryer particulate matter emissions. At lower than 70 mg/dscm, this 

trade-off Is not as favorable due to the 

energy requirements of venturi scrubbers 

at higher pressure drops. For this source, 

alternative means of air pollution control 

have not been fully demonstrated. Having considered all comments on the par2233 

tlculate matter regulation proposed for 

thermal dryers, EPA finds no reason sufficient to alter the proposed standard of 

70 mg/dscm except to restrict its appUcabillty to thermal dryers processing 

bituminous coal. 

3. Location of thermal drying systems.—Comments were received on the 

applicability of the standard for power 

plants with closed thermal drying systems where the air used to dry the coal ls 

also used in the combustion process. As 

Indicated ln j 60.252(a). the standard is 

concerned only with effluents which are 

discharged into the atmosphere from the 

drying equipment. Since the pulverized 

coal transported by heated air ls charged 

to the steam generator in a closed system, 

there Is no discharge from the dryer directly to the atmosphere, therefore, these 

standards for thermal dryers are not applicable. Effluents from steam generators 

are regulated by standards previously 

promulgated (40 CFR Part 60 subpart 

D). However, these standards do apply 

to all bituminous coal drying operations 

that discharge effluent to the atmosphere 

regardless of their physical or geographical location. In addlttona to thermal 

dryers located In coal preparation plants, 

usually ln the vicinity of the'mlnes, dryers used to preheat coal at coke ovens are 

alsorcgulated by these standards. These 

coke oven thermal dryers used for preheating are similar In all respects, including the air pollu yon control equipment, to those used ln coal preparation 

plants. 

4. Opacity standards.—The opacity 

standards for thermal dryer' and pneumatic coal cleaners were reevaluated as 

a result of revisions to Method 9 for conducting opacity observations (39 FR 

39872). The opacity stndards were proposed prior to the revisions of Method 9 

and were not based upon the concept of 

averaging sets of 24 observations for sixminute periods. As a result, the proposed 

standards were developed In relation to 

the peak emissions of the facility rather 

than the average emissions of six-minute 

periods. The opacity data coUected by 

EPA have been reevaluated in accordance 

with the revised Method 9 procedures, 

and opacity standards for thermal dryers and pneumatic coal cleaners have 

been adjusted to levels consistent with 

these new procedures. The opacity standards for thermal dryers and pneumatic 

coal cleaners have been adjusted from 30 

and 20 percent to 20 and 10 percent 

opacity, respectively. Since the proposed 

standards were based upon peak rather 

than average opacity, the revised standards are numerically lower. Each of these 

levels ls Justified based primarily upon 

slx-mlnute averages of EPA opacity observations. These data are contained in 

Section IH. Volume 3 of the supplemental 

background Information document. 

5. Fugitive ' emission monitoring.—• 

Several commentators identified some 

difficulties with the proposed procedures 

for monitoring the surface moisture of 

thermally dried coal. The purpose of the 

proposed requirement waa to determine 

the probability of fugitive emissions occuring from coal handling operations 

FEDERAL REGISTER, VOL. 41 , NO. 10—THURSDAY, JANUARY 15, 1.976 

A-3 
P.32 

2234 

and to estimate their extent. The commentators noted that the proposed 

A.S.T.M. measurement methods are difficult and cumbersome procedures not 

typically used by operating faculties. 

Also, it was noted that there ls too little 

uniformity of techniques within Industry 

for measuring surface moisture to specify a general method. Secondly, estimation of fugitive emissions from such 

data may not be consistent due to different coal characteristics. Since the opacity standard promulgated herein can 

readily be utilized by enforcement personnel, the moisture monitoring requirement ls relatively unimportant. EPA has 

therefore eliminated this requirement 

from the regulation: 

6. Open storage piles.—The proposed 

regulation applied the fugitive emission 

standard to coal storage systems, which 

were defined as any faculty used to store 

coal. It was EPA's Intention that this 

definition refer to some type of structure 

such as a bin, silo, etc. Several commentators objected to the potential application of the fugitive emission standard to open storage piles. Since the 

fugitive emission standard was not developed for application to open storage 

piles, the regulations promulgated herein clarifies that open storage piles of coal 

are not regulated by these standards. 

7. Thermal dryer monitoring equipment.—A number of commentators felt 

that Important variables were not being 

oonsldered for monitoring venturi scrubber operation on thermal dryers. The 

proposed standards required monitoring 

the temperature of the gas from the 

thermal dryer and monitoring the 

venturi scrubber pressure loss. The 

promulgated standard requires, ln addition to the above parameters, monitoring of the water supply pressure to the 

venturi scrubber. Direct measurement 

of the water flow rate was considered 

but rejected due to potential plugging 

problems as a result of solids typically 

found in recycled scrubber water. Also, 

the higher oost of a flow rate meter ln 

comparison to a simpler pressure monitoring devloe was a factor in tiie selection of a water pressure monitor for 

verifying that the scrubber receives adequate water for proper operation. This 

revision to the regulations will Insure 

monitoring of major air pollution control 

device parameters subject to variation 

which could go undetected and unnoticed 

and could grossly affect proper operation of the control equipment A pressure 

sensor, two transmitters, and a two pen 

chart recorder for monitoring scrubber 

venturi pressure drop and water supply 

pressure, which are commercially avaUable, will oost approximately two to three 

thousand dollars Installed for each 

thermal dryer. This cost ls only onetenth of one percent of the total Investment cost of a 500-ton-per-hour thermal 

dryer. The regulations also require monitoring of the thermal dryer exit temperature, but no added cost wiU result 

because this measurement system ls 

normally suppUed with the thermal drying equipment and ls used as a control 

point for the process control sysiem. 

RULES AND REGULATIONS 

Effective date.-'In accordance with 

section 111 of the Act, as amended, these 

regulations prescribing standards of 

performance for coal preparation plants 

are effective on January 15, 1976, and 

apply to thermal dryers, pneumatic coal 

cleaners, coal processing and conveying 

equipment, coal storage systems, and 

coal transfer and loading systems, the 

construction or modification of which 

was commenced after October 24, 1974. 

Dated: January 8, 1976. 

RUSSELL E. TRAIN, 

administrator. 

Part 60 of Chapter I of Title 40 of the 

Code of Federal Regulations Is amended 

as follows: 

1. The table of contents ls amended by 

adding subpart Y as follows: 

Subpart Y—Standarda of Performs net for Coal 

Preparation plants 

Sec. 

60.2 60 

60.261 

60.2S3 

60.253 

60.264 

Applicability and dealgnatlon of 

afTected facility. 

Definitions. 

Standards for particulate matter. 

Monitoring of operations. 

Teet methods and procedures. 

A-oTKOKrrT: Sees. 111 and 114 of the Clean 

Air Ace, as-amended by sec. 4(a) of Pu-i. L. 

91-604, to Stat. 1678 (42 0.S.C. 1857&-6, 1867 

C-B). 

2. Part 60 ls amended by adding subpart Y as follows: 

• * * e • 

Subpart Y—Standards of Performance for 

Coal Preparation Plants 

§ 60.250 Applicability and designation 

of affected facility. 

The provisions of this subpart are 

applicable to any of the following affected facilities in coal preparation plants 

which process more than 200 tons per 

day: thermal dryers, pneumatic coalcleaning equipment (air tables), coal 

processing and conveying equipment (Including breakers and crushers), coal 

storage systems, and coal transfer and 

loading systems. 

§ 60.25 1 D*6nitions. 

As used ln this subpart, all terms not 

denned herein have the meaning given 

them ln the Act and ln subpart A of this 

part. 

(a) "Coal preparation plant" means 

any facility (excluding underground 

mining operations) which prepares coal 

by one or more of the following processes: breaking, crushing, screening, wet 

or dry cleaning, and thermal drying. 

<b) "Bituminous coal" means solid fossil fuel classified as bituminous coal by 

A.8.T.M. Designation 73-388-66. 

(c) "Coal" means all solid fossil fuels 

classifled as anthracite, bituminous, subbituminous, or lignite by AJB.T.M. Designation D-388-66. 

(d) "Cyclonic flow" means a splrallng 

movement of exhaust gases within a duct 

or stack. 

(e) "Thermal dryer" means any facility ln which the moisture content of 

bituminous coal Is reduced by contact 

with a heated gas stream which is exhausted to the atmosphere. 

(f) "Pneumatic coal-cleaning equipment" means any facility which classifies 

bituminous coal by size or separates bituminous coal from refuse by application 

of atr stream(s). 

(g) "Coal processing and conveying 

equipment" means any machinery used 

to reduce the size of coal or to separate 

coal from refuse, and the equipment used 

to convey coal to or remove coal and 

refuse from the machinery. This Includes, but ls not limited to, breakers, 

crushers, screens, and conveyor belts. 

(h) "Coal storage system" means any 

facility used to store coal except for open 

storage piles. 

(1) "Transfer and loading system" 

means any facility used to transfer and 

load coal for shipment. 

§ 60.252 

ter. 

Standards for particulate mal-

(a) On and after the date on which 

the performance test required to be conducted by j 60.8 is completed, an owner 

or operator subject to the provisions of 

this subpart shall not cause to be, discharged mto the atmosphere from any 

thermal dryer gases which: 

<1) Contain particulate matter in excess of 0.070 g/dscm (0.031 gr/dscf). 

'2> Exhibit 20 percent opacity or 

greater. 

(b> On and after the date on which the 

performance test required to be conducted by % 60.8 Is completed, an owner 

or operator subject to the provisions of 

this subpart shall not cause to be discharged Into the atmosphere from any 

pneumatic coal cleaning equipment, 

gases which: 

(1) Contain particulate matter in excess of 0.040 g/dscm (O.OU gr/dscf). 

(2) Exhibit 10 percent opacity or 

greater. 

' (c) On and after the date on which 

ths performance test required to be conducted by I 60.8 Is completed, an owner 

or operator subject to the provisions of 

this subpart shall not cause to be discharged Into the atmosphere from any 

coal processing and conveying equipment, coal storage system, or coal transfer and loading system processing coal. 

gases which exhibit 20 percent opacity 

or greater, 

§ 60.25 3 Monitoring of operations. 

(a) The owner or operator of any thermal dryer shall Install, calibrate, maintain, and continuously operate monitoring devices as f oDows: 

(1) A monitoring devloe for the measurement of the temperature of the gas 

stream at the exit of the thermal dryer 

on a continuous basis. The monitoring 

device Is to be certified by the manufacturer to be accurate within* 3* Fahrenheit 

(2) For affected facilities that use venturi scrubber emission control equipment: 

(1) A monitoring device for the continuous measurement of the pressure loss 

through the venturi constriction of the 

FEDERAL IEGISTER, VOL. 41, NO. 10—THUBSOAY, JANUAIY 15, 1976 

A-4 
control equipment. The monitoring device la to be certified by the manufacturer to be accurate within ± 1 Inch 

water gage. 

(11) A monitoring device for the continuous measurement of the water supply pressure to the control equipment. 

The monitoring device ls to be certified 

by the manufacturer to be accurate within ±5 percent of design water supply 

pressure. The pressure sensor or tap must 

be located close to the water discharge 

point. The Administrator may be consulted for approval of alternative locations. 

(b) All monitoring devices under paragraph (a) of this section are to be recalibrated annually In accordance with procedures under S 60.13(b) (3) of this part. 

§ 60.254 Teat methods and procedures. 

(a) The reference methods ln Appendix A of this part, except as provided 

ln j 60.8(b), are used to determine compliance with the standards prescribed ln 

> 5 60.252 as follows: 

(1) Method 5 for the concentration of 

. particulate matter and associated moisture content, 

(2) Method 1 for sample and velocity 

traverses, 

(3) Method 2 for velocity and volumetric flow rate, and 

(4) Method 3 for gas analysis. 

-(b) For Method 5, the sampling time 

for each run ls at least 60 minutes and 

the minimum sample volume ls 0.85 dscm 

(30 dscf) except that shorter sampling 

times or smaller volumes, when necessitated by process variables or other factors, may be approved by the Administrator. Sampling ls not to be started until 

30 minutes after start-up and ls to be 

terminated before shutdown procedures 

commence. The owner or operator of the 

affected facility shall eliminate cyclonic 

flow during performance tests ln a manner acceptable to the Administrator. 

(c) The owner or operator shall construct the facility so that particulate 

emissions from thermal dryers or pneumatic coal cleaning equipment can be 

accurately determined by applicable test 

methods and procedures under paragraph (a) of this section. 

(FR DQC.10-124 0 Filed 1-14-70:8:45 am] 

~~ — — P,33_ 

RULES AND REGULATIONS 2205 

FEDERAL REGISTER, VOL 41 . NO. IO—THURSDAY JANUARY 13, 1974 

A-5 
P.34 

APPENDIX B 

STANDARD TEST METHODS 

B-l 
P.35 

Appendix A—Reference Methods 

.! i 

I' • 

METHOD 1—SAMPLE AND VELOCITY TRAVEB5E3 

TOR BTATIOr-rARY SOUBCE3 

1. Principle and Applicability. 

1.1 Principle. A sampling Bite and the 

number of traverse points are selected to aid 

ln the.extraction of a representative sample. 

1.2 Applicability. ThlB method should 

be applied only when specified by the test 

procedures for determining compliance with 

the New Source Performance Standards. Unless otherwise specified, this method IB not 

Intended to apply to gas streams other than 

those emitted directly to the atmosphere 

without further processing. 

2. Procedure. 

2.1 Selection of a sampling site and minimum number of traverse points. 

2.1.1 Select a sampling site that ts at least 

eight stack or duct diameters downstream 

and two dlameterB upstream from any now 

disturbance such as a bend, expansion, contraction, or visible name. For rectangular 

cross section, determine an equivalent diameter from the following equation: 

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

1 equation 1-1 

2:i.2; When the above sampling site 

criteria can.be met, the minimum number 

of traverse points ls twelve (12). 

2.1.3 Some sampling situations render the • 

above sampling site criteria impractical. 

When this Is the case, choose a convenient 

sampling location and use Figure 1-1 to determine the minimum number of traverse 

points. Under no conditions should a sampling point be selected within 1 Inch of the 

stack wall. To obtain the number of traverse 

points for stacks or ducts with a diameter 

less than 2 feet, multiply tbe number of 

points obtained from Figure 1-1 by 0.87. 

2.1.4 To use Figure J-l first measure the 

distance from the chosen sampling location 

to the nearest upstream and downstream disturbances. Determine the corresponding 

number of traverse points for each distance 

from Figure 1-1. Select the higher of the 

two numbers of traverse points, or a greater 

value, such that for circular stacks the number is a multiple of 4. and for rectangular 

stacks the number follows the criteria of 

section 2.2.2. 

2.2 Cross-sectional layout and location of 

traverse points. 

2.2.1 For circular stacks locate the traverse points on at least two diameters according to Figure 1-2 and Table 1-1. The 

traverse axes shall' divide the stack cross 

section Into equal parts. 

2.2.2 For rectangular stacks divide the 

cross section Into as many equal rectangular 

areas as traverse points, such that the ratio 

of the length to the wldll: of the elemental 

areas la between om and two. Locate the 

traverse points <vt the centroid of each equal 

area-acoordlng o Figure 1-3. 

3. Reference!. 

Determining Dust Concentration In a Cns 

Stream, ASME Performance Test Code -27, 

New York, N.Y.. 1957. 

Devorkln. Howard, et al.. Air Pollu lion 

Source Testing Manual. Air Pollution Control 

District. Los Angeles. Calif. November 1963. 

Methods for Determination of Velocity. 

Volume. Dust and Mist Content of Gases, 

Western Precipitation Division of Joy Manufacturing Co., Los Angeles, Calif. Bulletin 

WP-50. 1968. 

Standard Method for Sampling Stacks for 

Particulate Matter. In: 1971 Book of ASTM 

Standards, Part 23. Philadelphia, Pa. 1971. 

ASTM Designation D-2328-71. 

NUMBER OF DUCT DIAMETERS UPSTREAM' 

[DISTANCE At 

2.5 

,XI7DISTUHBANCE 

. SAMPLINQ 

"SITE 

DISTURBANCE 

•FfiOM POINT OF ANY TYPE OF 

DISTURBANCE (BEND, EXPANSION, CONTRACTION. ETC.) 

» 

NUMBER OF DUCT-DIAMETERS DOWNSTREAM* 

(DISTANCE B) 

Figure W . Minimum number of traverse points. 

Figure 1-2. Cross section of circular stack divided into 12 equal 

areas, sho.ving location of traverse points at centroid of each area. 

x 

B-2 
P.36 

Table 1-1. Location of traverse points in circular stacks 

(Percent of stack diameter from inside wall to traverse point) 

Traverse 

point 

number 

diameter 

1 

2 

3 

4 

5 

6 

7 

8 

9 

10 

11 

12 

13 

14 

15 

16 

17 

IB 

19 

20 

21 

22 

23 

24 

2 

14.6 

85.4 

4 

i.i 

25.0 

75.0 

93.3 

Number of traverse points 

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 

12 

2.1 

6.7 

11.8 

17.7 

25.0 

35.5 

64.5 

75.0 

82.3 

88.2. 

53.3 

97.9 

14 

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 

on a diameter 

16 

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 

18 

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 

20 

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 

.24 

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 

! i i 

O | O | O I o 

I I • 

I I I 

— r T 

! ' * 

O | o t o 1 o 

< I I 

1

 ' I 

Figure 1-3. Cross section of rectangular'stack divided into 12 equal 

areas, with traverse points at centroid of each area. 

B-3 
P.37 

METHOD J—DETERMINATION Or STACK CAS 

VELOCITY AND VOLUMETRIC TLOW HATE (TYTE 

S PITOT TUBE) 

1. Principl e and applicability. 

1.1 Principle . Stack gas velocity ls determine d rrom th e gas density an d fiom mea.suremen t of th e velocity hea d using a Type S 

(Stauschelb e or reverse type ) pito t tube . 

l.a Applicability. This metho d shoul d lie 

applied only when specified by th e test pro -

cedure s for determinin g complianc e with th e 

New Source Performanc e Standards. 

2. Apparatus. 

2.1 Pito t tube—Typ e S (Figur e 2-1), or 

equivalent, with a coefficient withi n ±5 % 

over th e working range . 

2.2 Differential pressur e gauge—Dicllncd 

manometer, or equivalent, to measur e velocity hea d t o withi n 10% of th e minimu m 

value . 

2.3 Temperatur e gauge—Thermocoupl e or 

equivalen t attache d to th e pito t tub e to 

measur e stack temperatur e to withi n 1.5% of 

t h e minimu m absolut e stack temperature . 

2.4 Pressur e gauge—Mercury-fiiled U-tub e 

manometer, or equivalent, to measur e stack 

pressur e to within 0.1 In. Hg. 

2.5 Barometer—To measur e atmospheri c 

pressur e to withi n 0.1 In. Hg. 

- 2,6 Gas analyzer—To analyz e gas composl-

• tlon for determinin g molecula r weight. 

2.7 Pito t tube—Standar d type , to calibrat e Type S pito t tube . 

* 3. Procedure. 

3.1 Set u p th e apparatu s as shown in Figu r e 2-1 . Make sur e all connection s are tigh t 

a n d leak free. Measur e th e velocity head an d 

temperatur e a t th e travers e points specified 

by Method 1. 

3.2 Measur e th e stati c pressur e in th e 

stack. 

3.3 Determin e th e stack gas molecula r 

weight by gas analysis an d appropriat e calculation s as indicated In Method 3. 

4. Calibration. 

4.1 To calibrat e th e pito t tube , measur e 

t h e velocity head a t some poin t In a flowing 

ga s stream with bot h a Type S pito t tub e an d 

a standar d type pito t tub e with known coefficient. Calibration shoul d be don e in th e 

laboratory an d th e velocity of th e flowing g;>--5 

stream shoul d be varied over th e norma l 

workin g range . It ls recommende d tha t th e 

calibratio n be repeated after us e a t each field 

site . 

4.2 Calculat e th e pito t tub e coefficient 

usin g equatio n 2-1 . 

C =C A-M'.m 

V aiv. i equatio n ---1 

where : 

C», P ., = Pltot tub e coefficient of Type S 

pito t tube . 

Cp, t J=-Pitot tub e coefficient of standar d 

type pito t tub e (lf unknown , use 

0.99 j . 

-lp,id= Velocity head measure d by stand -

ard type pito t tube , 

dpi.«i = Velocity head measure d by Type S 

pitot tube . 

4.3 Compar e th e coefTlclenU of th e Type S 

plbot tub e determine d first wit h on e leg an d 

the n th e othe r pointed downstream. Use th e 

pito t tub e only if th e two coefficients differ by 

n o mor e tha n 0.01. 

5. Calculations. 

Dse equatio n 2-2 to calculat e th e stack gas 

velocity. 

Equatio n 2- 2 

where: 

(V,)..,, = Slack RM velocity. Wl per second (f.i'.s.). 

KD-=8fi.*JR—(--—.'.•_. J "when those •••lus sec.Vlb. mole- 11/ 

ore used. 

(-',.-= I'llot lube cnefliiii'tit, rthncnslonless. 

(T.l,„.HAverage absolute stack giis Iciiiiicr-i.hire, 

"R. 

vivace velocity lieail of stack c:is, Indira 

HlO (See Fiji. 2-2). 

!', = Absolute Stack pas pressure, Indies Up. 

M,-a Molecular weight of stack gas (wet l.msis), 

11>./lb.-mole. 

Md(l-H. D )+!Rn. n 

Md = Pry molecular wight of stack j-ns (from 

Metiiod 3). 

B.o=Pi'oiwlion by volume, of water i*n|>of In 

the cas stream (from Method 4). 

Figur e 2-2 shows a sampl e recording shee t 

for velocity traverse data . Use th e averages 

l n th e last two column s of Figure 2-2 t o de -

termin e th e average stac k gas velocity from 

Equatio n 2-2. 

Use Equatio n 2-3 to calculat e th e stack 

ga s volumetri c flow rate . 

Q.-Moo(i-B„)v.A(rT;--)(]|;t) 

Equatio n 2-?i 

where: 

Q.=Voliinietik- fhtu- rale, dty basis, standard conditions, ft.yiir. 

A = Cross-5oct]in*alnrcflL-r stuck, fi.* 

Tm***1 Absolute temperature at standard conditions-, 

630° B. 

Ptn = Aiisohitn pressure at standard conditions, 29.03 

Indie;* Ug. 

6. References. 

Murk. L. S„ Mechanica l Engineers' Humi 

book, McOraw-HIIl Book Co., Inc., New York" 

N Y , 1951. 

Perry. J. H.. Chemical Engineers' Hand 

book, McGraw-Hill Book Co., Inc., New Ynrtr" 

N.Y.. I0GO. ' 

Sliigchara. R. T., W. F. Todd, and w s 

Smith . Significance of Errors in Stack Sam-. 

pllng Measurements. Paper presented nt the 

Annua l Meeting of the Air Pollution Control 

Association, St. Louis. Mo.. Jun e 14-19, iflio 

Standar d Method for Samplin g Stacks for 

Particulat e Matter. In : 1971 Book of ASTM 

Standards, Part 23, Philadelphia , p a 1971 

ASTM Designation D-2D2B-71. 

Vcnuard. J. K.. Elementary Fluid MechanIrs. Joh n Wiley & Sons. Inc., New York NY " 

1947. ' -

PIPE COUPLING TUBING ADAPTER 

Figure 2-1. Pitot tube-manometer assembly. 

B-4 
P.38 

PLANT 

DATE, 

RUN NO. 

STACK DIAMETER, in. 

BAROMETRIC PRESSURE, in. Hg. 

STATIC PRESSURE IN STACK {Pg), in. Hg. 

OPERATORS SCHEMATIC OF STACK 

CROSS SECTION 

Traverse point 

number 

Velocity head, 

in. H20 

AVERAGE: 

v£7 

' 

Slack Temperature 

rts>.°f 

Figure 2-2. Veioclly traverse dala. 

B-5 
P.39 

MITT HOO 3—CAS ANALYSIS TOR CARSON DIOIIDI, 

EXCESS Ala, ANO DBT MOLECTTLA* WKICHT 

1. Principle and applicability. 

1.1 Principle. An Integrated or grab gas 

sample Is extracted from a sampling point 

and analyzed for Its components using an 

Orsat analyzer. 

1.2 Applicability. This method should be 

applied only when specified by the test procedures for determining compliance with tbe 

New Source Performance Standards. The test 

procedure will Indicate whether a grab sample or an Integrated sample Is to be used. 

2. Apparatus. 

2.1 Grab sample (Figure 3-1). 

2.1.1 Probe—Stainless steel or Pyrex1 

glass, equipped with a filter to remove particulate matter. 

2.1.2 Pump—One-way Bqueeze bulb, or 

equivalent, to transport gas sample to 

analyzer. 

»Trade name. 

3.2 integrated sample {Figure i-2). 

3.2.1 Probe—Stainless steel or Pyrex1 

glass, equipped witb * Alter to remove particulate matter. 

2.2 J Air-cooled condenser or equivalent— 

To remove any excess moisture. 

3.2.3 Needle valve—To adjust flow rate. 

2.2.4 Pump—Leak-free, diaphragm type, 

or equivalent, t o pull gas. 

2.2.5 Rate meter—To measure a flow 

range from 0 to 0.035 cfm. 

3.2.a Flexible bag—Tedlar,1 or equivalent, 

with a capacity of 2 to 3 cu. ft. Leak test the 

bag ln the laboratory before using. 

2.2.7 Pitot tube—Type S, or equivalent, 

attached to the probe BO that the sampling 

flow rate can be regulated proportional to 

the stack gas velocity when velocity Is varying with time or a sampla traverse La 

conducted. 

2.3 Analgia. 

3.3.1 Orsat analyzer, or equivalent. 

PR08 PR E ' FLEXIBLE TUBING 

TO ANALYZER 

/ 

FILTER (GLASS NOOl) 

SQUEEZE BULB 

Figure 3-1 . Grab-sampling train. 

RATE METER 

VALVE 

AIR-COOLED CONDENSER 

PROSE 

FILTER [GLASS WOOL} 

QUICK DISCONNECT 

A 

RIGID CONTAINER^ 

Figure 3-2* Integrated gas • sampUng train. 

3. Procedure. 

3.1 Grab sampling. 

3.1.1 Set up the equipment as shown In 

Figure 3-1, making sure all connections are 

leak-free. Place the probe In the stack at a 

sampling point and purge the sampling line. 

3.1.2 Draw sample into the analyzer. 

3.2 Integrated sampling. 

3.2.1 Evacuate the flexible bag. Set up the 

equipment tm shown in Figure 3-2 with the 

bag disconnected. Place the probe In the 

stack and purge the sampling line. Connect 

the bag, making sure tha t all connections are 

tight and that there are no leaks. 

3.2.3 Sample at a rate proportional to the 

stack velocity. 

3.3 Analysis. 

3.3.1 Determine the CO., O,. and CO concentrations as soon «a possible. Make as many 

passes as are necessary to give constant readings, if more than ten p&mes are necessary, 

replace the absorbing solution. 

3.3.2 For grab sampling, repeat the sampling and analysis until three consecutive 

samples vary no more than 0.5 percent by 

volume tor each component being analyzed. 

3.3.3 For Integrated sampling, repeat the 

analysis of tive sample until three consecutive analyses vary no more than 0.2 percent 

by volume for each component being 

analyzed. 

4. Calculations. 

4.1 Cartwn dioxide. Average the three consecutive runs and report the result to the 

nearest 0.1% COr 

4.2 Excess air. Use Equation 3-1 to calculate exce-ss air. and average the runs. Report 

the result to the nearest 0.1 % exoees air. * 

%UA = 

(%Oi)-0.S(%CO) „ lft n 

0.2G4(% N,)-( % O.)+0.5(% C0) AiU U 

equation 3-1 

•where: 

%EA = Percent excess air. 

% 0 , = Percent oxygen by volume, dry basis. 

%NJ-=Percent nitrogen by volume, dry 

basis. 

%CO=-Percent carbon monoxide by volume, dry basis. 

0.2*4-= Ratio of oxygen to nitrogen ln air 

by volume. 

4.3 Dry molecular weight. Use Equation 

3-2 to calculate dry molecular weight and 

average the runs. Report the result to the 

nearest tenth. 

M* = 0.44(%CO,)-f0.32{%03) 

+ 0.28(%N,+ %CO) 

equation 3-2 

where: 

Ma=Dry molecular weight, lb./lb-mole. 

%CO*-=Percent carbon dioxide by volume, 

dry basis. 

"iOfspercent oxygen by volume, dry 

basis. 

%N-j=Percent nitrogen by volume, dry 

basts. 

0.44=Moleculax weight of carbon dioxide 

divided by ioo. 

0.32=Molecular weight of oxygen divided 

by 100. 

0.28=Molecular weight of nitrogen and 

CO divided by 10O. 

fl. Rt ferences. 

Altahuller, A. P.. et al.. Storage of Oases 

and Vapon In Plastic Bags. Int. J. Air & 

Water Pollution. 6:75-81, 1983. 

Conner. William D.. and J. 8. Nader, Air 

Sampling with Plastio Bags, Journal of tha 

American Industrial Hygiene Association, 

25:291-297, May-June 1964. 

Devorkin, Howard, et al.. Air Pollution 

Source Testing Manual, Air Pollution Control District, Loa Angeles, Calif., November 

1993. 

ii 

B-6 
P.4Q 

METHOD 5—DETERMINATION or PARI icn.ATE 

EMISSIONS Fnoin STATIONARY SOURCES 

1. Principe and aiiphcnhility. 

1 1 Principle. Particulate matter i.s withdrawn lsoklnctlcally from the sonrre and ils 

weight is determined gr.ivtnietrlcnlly after removal of uncombined water. 

1.2 Applicability. This ni^tliod Is ayiplir.iUie lor the determination ni pnrtlculale emissions fmm stationary sources only when 

specified by the test procedures for determining compliance with New Source Performance Siandards. 

2. Apparatus. 

2 I Sampling train. The design -specifications of the paniculate sampling train iced 

by EPA (Figure 5-1) arc described In APH)-

0581. Commercial models ol this train are 

available. 

2.1.1 Noz?.le—Stainless steel (31G) with 

sharp, tapered leading cfic. 

2 1.2 Probe—Pyrex1 glass with a healing 

system capable or maintaining a minimum 

gas temperature of 250" F. at the extt. end 

during sampling to prevent condensation 

fp'in occurring. When length llmltal-hms 

(greater than about 8 ft.) are encountered at 

temperatures Ic-'-s than GOO"" F.. Incoloy (12.I ', 

or equivalent, may be used. Probes for sampling gas'streams al temperatures ln excess 

of 600" F. must have been approved by the 

Administrator.-

2.13 Pitot tube—Type S. or equivalent, 

attached lo probe to monitor stack gas 

velocllv. 

2.1.4 Filler Holder—Pyrex' glass with 

he-allng system capable of maintaining minimum temiwraLure of 225" F. 

2.1.5 Impingera / Condenser—Four impingers connected ln fierics with gla&s ball Joint 

llttlngs. The first, third, and fourth impingers ore of the Green burg-Smith design, 

modified by replacing the tip with a '/-.-Inch 

ID glass tube extending to one-half Inch 

from the bottom of the flask. The second impinger ls or the Greenburg-Smith design 

with tlie standard tip. A condenser may be 

used tn place of the Impingers provided that 

the moisture content of the stack gas can 

still he determined. 

2.1.6 Metering system—Vacuum g;iugc, 

leak-free pump, thermometers capable of 

measuring temperature Lo within 5* F., dry 

gas meter with 2% accuracy, find related 

equipment, or equivalent, as required to 

mainUilti an Ir-ok luetic sampling rate nnd to 

determine sample volume. 

2.1.7 Barometer—To measure atmospheric 

pressure to -£0.1 Inches Hg. 

2.2 Sample recovery. 

2 2.1 Probe brush—At least as long as 

probo. 

2.2.2 Glmw wash bottles—Two. 

2.2.3 Glass sample storage containers. 

2 2.4 Graduated cylinder—250 ml. 

2.1 Analysis. 

2.3 1 Ola.-.s weighing dishes. 

2.3.2 Deslce.ilor. 

2.1.3 Analytical balance—To measure to 

±0.1 mg. 

2.1 1 Trip balance—300 g. capacity, to 

tnennure lo -+-0.05 g. 

3 Rcartrnts. 

3.1 Sampling. 

3.1.1 Fillers—Glass fiber. MSA 1100 HH'. 

or equivalent, numbered for Identification 

and pre weighed. 

3.1.2 Silica get—TiHlicatlng type. 0-10 

mesh, dried at 176* C. (350* F.) for 2 hours. 

3.1.3 Water. 

3.1.4 Crushed Ice. 

3.2 Sample recovery. 

•* 2.1 Acetone—Reagent grade. 

3.3 Analysis. 

3.3.1 Water. 

IMPINGER TRAIN OPTIONAL. HAY BE REPLACED 

BY AN EQUIVALENT CONDENSER 

HEATED AREA FILIER HOLDER / THERMOMETER CHECK 

PROBE 

REVERSE-TYPE 

PITOT TUBE 

VX 

PIT01 MANOMETER 

ORIFICE 

IMPINGERS ICE BATH 

BY-PASS VALVE 

31 

THERMOMETERS 

VALVE 

„VACUU M 

LINE 

\ VACUUM 

\ GAUGE 

MAIN VALVE 

7 ' /•" 

OR* TEST METER AIR-TIGHT 

PUMP 

Figure 5-1. Paniculate-sampling bain. 

3.3.2 Dcslrxnnl -Dricrtte.' Indicating. 

4. Procedure. 

4.1 .Sampling 

4.1.1 After sel ed.In*; (he sampling site and 

tho minimum number of sampling point-;, 

determine the stack pressure, temperature, 

moisture, and range of velocity head. 

4.1 2 Preparation of collection train. 

Weigh to the nearest grnm approximately 200 

g. of silica gel. Label a filter of proper diameter. desiccate1

 for at least 24 hours and 

weigh to the nearest 0.5 mg. In a room where 

tlic relative humidity ts less than 50'; . Place 

100 ml. of water In each of the first iwo 

Impingers, leave the third Impinger empty, 

ami place approximately 200 g. of prcweiglied 

sltlra gel In the fourth impinger. He I. up the 

train without the protic as In Figure 5-1. 

Leak check the snmpliui: train at tlie .'.:impllng sila liy plugging up tlie Inlet to 1 lie filter ivildur nnd pull hit: a 15 in. Hg vacuum. A 

lenkage rate not In excess of 0.02 c.f.ni. at a 

vacuum <;f 15 In. Hg is acceptable. Attach 

the probe and adjust the heater to provide; n 

gas temperature o'f about 250° F. at the probe 

outlet. Turn on the filter heating system. 

Plate crushed Ice around the Impingers. Add 

more tec during the run to • eep the temperature or !h" gases leaving the last Impinger 

as u»v.- as possible and preferably at 70" F. 

or ie.*-s. Temperatures above 70° P. may result, 

in damage to the dry [jns meter from either 

moisture condensation or excessive heat. 

4.1.3 Particulate train operation. For each 

run, record the data required on the example 

sii let shown In Figure S-2. Tnkc reading.-; ;it 

cae.ii sampling point, nl least every 5 minutes, 

nud when significant changes In stack conditions necessitate additional ndjustnieuts 

In flow mie. To begin sampling, position Win 

w>zr\" nt the first traverse pnhil with the 

tip puinting directly Into the gas stream, 

lrnnirdintcly start tlie pump and adjust u-e 

Ilow to Isokinetic conditions. Sample for n>, 

l^ast fj minutes at e;teh traverse point: saniplhiR linn: must tic the same tor each p:ilm. 

Mnhilnln Isokinetic sampling I Itrnught-ul HIP 

sampling period. Nomographs are nvnilM-lc 

which nicl in the rapid adjustment, of the 

sampling rate without other eompulnlluns. 

AP'l'l) 0570 details the procedure for usln»-

these tioinngrnphs. Turn off tlie pump at tbe 

conclusion or each run nud record the final 

readings. Remove the probe and nozzle Ir.-m 

the slack nnd handle In accordance with the 

sample recovery process described In section 

4.2. 

4.2 Sample recovery. Exercise care ln moving the collection train Trom the test site to 

the sample recovery area to minimize the 

loss of collected sample or the gain of 

extraneous particulate matter. Set aside a 

portion of the acetone used ln the sample 

recovery as a blank for analysis. Measure the 

volume of water from the first three Impingers, then discard. Place the samples In 

containers as follows: 

Container No. 1. Remove the filter from 

Its holder, place in this container, and seal. 

Container No. 2. Place loose particulate 

matter and acetone washings from all 

sample-exposed surfaces prior to the Alter 

In this container and seal. Use a razor blade, 

brush, or rubber policeman to lose adhering 

particles. 

Container No. 3. Transfer the silica gel 

from the fo\irth Impinger to the original container and seal. Use a rubber policeman as 

an aid ln removing silica gel from the 

Impinger. 

4.3 Analysis. Record the data required on 

the example sheet shown ln Figure 6-3. 

Handle each sample container as follows: 

Container No. 1. Transfer the filter and 

any loose particulate matter from the sample 

container to- a tared glass weighing dish, 

desiccate, and dry to a constant weight. Report results to the nearest 0.5 mg, 

Container No. 2. Transfer the acetone 

washings to a tared beaker and evaporate to 

dryness at ambient temperature and pressure. Desiccate and dry to a constant weight. 

Report results to the nearest 0.5 mg. 

Container No. 3. Weigh the spent silica gel 

and report to the nearest gram. 

5. Calibration. 

Use methods and equipment which have 

been approved by the Administrator to 

calibrate the orifice meter, pitot tube, dry 

gas meter, and probe heater. Recalibrate 

after each test series. 

0. Calculations. 

0.1 Average dry gas meter temperature 

and average orifice pressure drop. See data 

sheet (Figure 5-2], 

1

 Trade name. 

1

 Trade name. 

•Dry using Drlerlte

 l at 70' P.±10* F. 

B-r7 
P.41 

6.3 Dry ga s volume . Correct th e sampl e 

volume measure d by th e dry gas mete r to 

standar d condition s (70s F., 29.92 Inches Hg) 

by using Equatio n 5-1 . 

*m„d *»\ T ij v Pitd / 

("•" A>-

equation 5-1 

where : 

V-n.. Volume or gas sampl e throug h th e 

dry gas mete r (standar d conditions), cu. ft. 

V„, = Volume of gas sampl e throug h th e 

dry gas mete r (me ter conditions) . cu. ft. 

T,,,, " Absolute temperatur e a t standar d 

conditions. 630* R. 

T_- " Average dry gas mete r temperature , 

' R. 

P bir « . Barometri c pressure a t th e orifice 

meter, Inches Hg. 

AH = Average pressure dro p across th e 

orifice meter, Inches H.,0. 

13.6 = Speciflc gravity of mercury. 

P,,. = Absolute pressure a t standar d con -

ditions. 29.92 inche s Hg. 

6.3 Volume °t wate r vapor. 

:

pB.O RT.* lb. Y

-.--

v

«-5r=-T B ,O P.t: d 45 4 gm . 

•=0.0474^^* . 

m l . - 3 

equatio n 5- 2 

where : 

Vw ,j = Volume of wate r vapor in th e gas 

sampl e (standar d conditions), 

cu. ft. 

Vt,<= Tota l volume of liquid collected In 

Impingers an d silica gel (see Fig -

u r e 6-3), ml . 

p»1n= Density of water. 1 g./ml. 

M»,o = Molecular weight of water, l a lb./ 

lb.-mole. 

R-=Idea l gas constant . 21.83 Inches 

Hg—cu. ft./lb.-mole-'B. 

T., d = Absolute temperatur e ftt standar d 

conditions, 530* R. 

P l U = Absolute pressure a t standar d con -

ditions, 29.92 Inches Hg. 

6.4 Moistur e content. 

B.., = 

V-..H 

equation 5-3 

WIK*ID: 

lt.„ =]'rn|M)ii Inn l>y vuliiitiool wal PI vapor In the gas 

stream, ilinii-nKlonlei-s. 

v

-1„i=V<j]nni(' of water In tiie ens sample (si-iiul-ir-l 

coii<Jlllon.s),cu. ll. 

^ ".-j =>Vi)lume of (ins sample tliroiiRh tbo dry pos mi'lw 

(stnnilard conditions), cn. ft. 

6.5 Tota l particulat e weight. Determin e 

t h e tota l particulat e catch from th e su m or 

t h e weights on th e analysis dat a shee t 

(Figur e 5-3). 

0.6 Concentration . 

6.6.1 Concentratio n In gr./s.c.f. 

•'•-(ao,54£-.)0fc) 

equatio n 5- 4 

wliero: 

c'. = ConcfntnilIon of parLirnlute matter In sln<k 

cas, gr./s.cf,- dry basis. 

M,-=Tolnl amount of particulate raatler colled rd, 

IHR. 

*".id=Volumn of cas sample lliroueti dry gas nictor 

(standard conditions), cu. ft. 

mm M 

lOCMIOH. 

at«»io»_ 

out 

WHNO. 

SAU»U |01 K(\_ 

Willi 1(11*0. 

•lllltH, . 

**-ni»-iiiPt"fu*f_ 

|UOUUuCMfUUK_ 

A»UWD noi num. * _ 

mMfiwtsiTiwo 

ftm UNCTM. K 

WIHIW»J*tI*,t»._ 

nOUHIMiaStlTIW. 

r. "icro 

I u vi i^t roiNi 

Muvsa 

lOriL 

j*mi*« ) 

t « 

kVtfACt 

j un e 

Mft«u*t 

(f,l. ta. H-| 

scHcine w si->c" «o » veno* 

tivtunr c 

Uli. *f 

vtiocm 

m*o 

OlfKUNTIAl 

ACWK 

oiuicl 

Wil l 

.'III. 

In. IIjO IV- I n* 

GAtsiunt nupiMnwi 

Al 0*1 C«SUITf" 

n an 

""•in.'-*' 

..,. 

OUI IK 

II« eB1 l.*| 

t.e. 

»--«• 

u w ( era 

TIWUTUM. *•< 

lEVftllllWI 

ll*TM ; 

c«D[-ru< on 

uui •'•u i 

Fig,-

4.6.3 Concentratio n In lb./cu. ft. 

UiooowK_2>20fi , M. . 

equation 5-5 

where: 

c.=*> Concentration of pin llonbl n mal I IT In slack 

Kofl, Ib./s.c.l., dry biwis. 

4S3,ii00-=M(;/lb. 

MB = Total amount of pai lldilnle matter eo 11 acted, 

inc. 

V.„Hd-Volume of Ra." samplo through dry gas mMo" 

(standard comllltona), cu. ft. 

6.7 Isokineti c variation. 

I-T. •.[(2: 

002C7 in. Hg-cu. ft. 

ml-°R )v,.+^(p..+r|)](... 

eV.P.A„ 

equation 5-6 

V I I'l i 

I - l'>'iiiiit n( ls.ikl'11'iic siMtipliTir. 

Vlp-='i'ul;il vi.IIIIIII I'l lli-uiil MMOI'IIM] In lni|i|in:-is 

'anrl !UII<-;i i-d (!-*.••« Tic. fi--)). ml. 

.(Hi,r."-|trnslly of vat'T, 1 R./mt. 

It = I'l*-:*,! c:i*= CfiilftiHil., 21 >n Ini-liM llfi-cil . fl./llt. 

i.;»|.-°H. 

Miigo-M'-lKiilnr w.-lirhl of uritrr, 1.1 Ih./lli.-mol-*. 

Vn -Vtiliitiirti(p:)s'iiiii]i|i' tlilnilL-lilhr.drj-pa.'! irid*T 

(111-I ••'• emu I iii'HIS), rn. (I. 

TB. = Ali-i-ilutc flvfuic' dry g:» meter tuii-piT-ilnn; 

(«IM. l-lpntr d •.').•• It. 

I'i.,i* lliiruiiii-iiic ]ir<'5-.iin- nl suii|-l|ii|! Site, Irit-h^.--

II.-. 

All--Avmi'i-c |in--i«iiir> ilinp nrruss tho orlliio (*••« 

Mi.', ft J). Iiifhi-s Hi" . 

T.-nAliSirlnl.e iiTi'isii:i> stiti-k £n3 Innpornturo (i"*" 

I-'IK. f> 21,"It. 

fl—Tobii siuiiplini! tltiH*. min. 

V.*»Sliick p:is vrlin-iiy <*;ili:iil*i,|.*il by M-llin-l 2. 

I*:i|ii'ili.in 'J 2. ft friT. 

I',- AiiSiilulcsliirli (j;i* ] 11 rssurn, lnrli<*fl lip. 

' An-'Cinfs-.ci-fllnn-il or en nf rinzrle, ri\. ft. 

fi.8 Acceptable results. Th e follow! nc 

rniif-c sets tlie limit on acceptable Isokinetic 

samplin g results; 

Lf 00^. < I < 110%. th e results are scccpUiblc, 

otherwise, reject th o results an d repcaL 

t h o lest. 

7. llr/.-rrjirr.. 

Addendum to Specifications for Incinerator 

Tesiin p ftt Federal Facilities. PHS, NCAPC. 

Dec. fi. lfiC7. 

Martin. Robert M.. Constructio n DctnJls of 

Jr.r-1-.inrtlc Sourc e Samplin g Equipment. Ktivironmcntnl Protection Agency. APTD-05FH. 

Rom. Jerome J.. Maintenance . Calibration, 

a n d Operation ol Isokineti c Source Sampling Fqulpment. Environmenta l Protection 

ARCUCV. APTD-057C. 

Smith , W. S„ R. T. ShlRchnra. nnd W. P. 

Todd. A Method of Interpretin g Stac k Sampling D;iU\. Pape r presented a t th e 63d Annua l Meeting of th e Air Pollution Control 

A:i;;oc-latlon. St. Louis. Mo.. Jun e 14-19, 1970. 

Smith . W. S.. et al . Slack Ca s Sampling 

Improved nnd Simplified wit h New Equip -

ment . AI'CA pape r No. 67-119, 1067. 

Specifications for Incinerator Testing a t 

Federal Facilities, PHS. NCAPC, 1967. 

B - 8 
P.42 

PLANT, 

DATE 

RUN N0._ 

CONTAINER 

NUMBER 

1 

2 

TOTAL 

WEIGHT OF PARTICULATE COLLECTED, 

mg 

FINAL WEIGHT TARE WEIGHT WEIGHT GAIN 

FINAL 

INITIAL 

LIOUID COLLECTED 

TOTAL VOLUME COLLECTED 

VOLUME OF LIOUID 

WATER COLLECTED 

IMPINGER 

VOLUME, 

ml 

SILICA GEL 

WEIGHT, 

fl 

9" ml 

CONVERT WEIGHT OF WATER TO VOLUME BY DIVIDING TOTAL WEIGHT 

INCREASE BY DENSITY OF WATER. (1 g. nil): 

INCREASE 9 = VOLUME WATER, ml 

11 g/mt) 

Figure5-3 . Analytical data. 

B-9 
P.43 

•MFTKOH 0 VISTTAL DETER MITT ATION Of THE 

OPACTTT OF EMISSIONS FBOM STATIONABT 

SOURCES >n 

Many stationary sources discharge visible 

emissions Into tha atmosphere: these emissions are usually ln tbe shape of s plume. 

ThJa method Involves the determination of 

plume opacity by qualiaed observers. The 

method Includes procedures for tha training 

and certification of observers, and procedures 

to be used in tbe field for determination of 

plumd opacity. Tho appearance of a plume as 

viewed by an observer depends upon a number of variables, some of which may be controllable and aome of which may not be 

controllable ln the field. Variables which can 

be controlled to an extent to which they, no 

longer exert a significant Influence upon 

plume appearance Include: Angle of the observer with respect to tbe plume: angle of the 

observer with respect to tho sun; point of 

observation of attached and detached steam 

plume; and angle of the observer with respect to a plume emitted from a rectangular 

stack with a largo length to width ratio. The 

method Includes specific criteria applicable 

to these variables. 

Other variables which may not bo controllable In the field are luminescence and color 

contrast between the plume and the hackground against which the plume Is viewed. 

These variables exert an tniluenco upon tbe 

appearance-of a plume oa viewed by an observer. and1

 can affect the ability of the observer to accurately assign opacity values 

to the observed plume. Studies of the theory 

of plumo opacity and field studies have demonstrated that a plume la most viaible and 

presents the greatest apparent opacity when 

viewed against a contrasting background. It 

follows from this, and la confirmed by field 

trials, that tho opacity of a plume, viewed 

undrr conditions where a contrasting background Ls present can be assigned with th e 

greatest degree of accuracy. However, tbe potential for a positive error ls also the greatest 

when a plume ls viewed under such contrasting conditions. Onder conditions pretesting 

a l«sa contrasting background, the apparent 

opacity of a plume ls less and approaches 

zero as the color and luminescence contrast 

decrease toward zero. As a result, significant 

negative bias and negative errors can bo 

made when a plume is viewed undtr Imm 

contrasting conditions. A negative bias decreases rather than Increases the possibility 

that a plant operator will be cited for a violation of opacity standards dne to observer 

error. 

Studies have been undertaken to determine 

the magnitude of positive errors which can 

be made by qualified observers while reading plumes under contrasting conditions and 

using the procedures set forth ln this 

method. The results of these studies (Held 

trials) which Involve a total of 769 sets of 

25 readings each are as follows: 

(1) For black plumes (133 sets at a smoke 

generator), 100 percent of the sets were 

rend with a positive error - of leai than 7.5 

percent opacity: 93 percent were read with 

a positive error of less than 5 percent opacity. 

(3) For white plumes (170 sets at a smoke 

generator. 168 sets at a coal-fired power plant, 

203 sets at a sulfuric acid plant), 99 percent 

of the seta were read with a positive error of 

less than 7.5 percent opacity; 85 percent were 

read with a positive error oness than 5 percent opacity. 

The positive observational error ar^o-lated 

•with on average of twenty-flve readings is 

therefore established. The accuracy of- the 

method must be taken into account-when 

determining possible violations of applicable opacity standards,. 

T o r » set, positive error=average opacity 

determined by observers' 36 observationsaverage opacity determined from transmlssometer's 25 recordings. 

2. Principle and applicability. 

1.1 Principle. The opacity of emissions 

from stationary sources la determined visually by a qualified observer. -

1.2 Applicability. This method Is applicable for the determination of the opacity 

of emissions from stationary sources pursuant to 160.11(b) and for qualifying observers for visually determining opacity of 

emissions. 

2. Procedures. The observer qualified ln 

accordance with paragraph 8 of this method 

shall us© the following procedures for visually determining the opacity of emissions: 

2.1 position.-Ths qualified observer shall 

stand at a distance sufficient to provide a 

clear view of the emissions with the sun 

oriented ln the 140* sector to his back. Consistent with-maintaining the above requirement, tbe observer shall, as much as possible, 

make his observations from a position such 

that his line of vision ls approximately 

perpendicular to the plume direction, and 

when observing opacity of emissions from 

rectangular outlets (e.g. roof monitors, open 

baghouses, noncircular stacks), approximately perpendicular to tbe longer axis of 

the outlet. Tbe observer's line or sight should 

not include moro than one plumo at a time 

when multiple stacks are Involved, and In 

any case tbe observer should make his observations with his line of sight perpendicular to the longer axis of such a set of multiple stacks (e.g. stub stacks on baghouses). 

2.2 Field records. The observer Bhall record tbe name of the plant, emission location, type facility, observer's .name and 

affiliation, and the date on a field data sheet 

(Figure 9-1). The time, estimated distance 

to the emission location, approximate wind 

direction, estimated wind speed, description 

ot the sky condition (presence and color or 

clouds), and plume background ara recorded 

on a field data sheet at the time opacity readings are Initiated and completed. 

2.3 Observations. Opacity observations 

shall be made at the point of greatest opacity 

in that portion of the plume -where condensed water vapor is not present. The observer shsU not look continuously at the 

plume, but In*tend shall observe tbo plume 

momentarily at 15-sscond intervals. 

2.3.1 Attached steam plumes. When condensed water vapor ls present within the 

plume BS It emerges from the emission outlet, opacity observations shall be made beyond the point In the plume at which condensed water vapor Is no longer visible. The 

observer shall record tbe approximate distance from the emission outlet to the point 

In the plume at which tbe observations are 

made. 

2.35 Detached steam plume. When water 

vapor ln tbe plume condenses and becomes 

visible at a distinct distance from the emission outlet, the opacity of emissions should 

be evaluated at the emission outlet prior to 

the condensation of water vapor and tbe formation of the steam plume. 

2.4 Recording observations. Opacity observations shall be recorded to the nearest 5 

percent at 15-second intervals on an observational record sheet. (See Figure 9-2 for 

an example.) A minimum of 24 observations 

shall be recorded. Each momentary observation recorded shall bo deemed to represent 

the average opacity of emissions for a JpEecond period. 

2.5 Data Reduction. Opacity shall be determined as an averago of 24 consecutive 

observations recorded at 15-eecond intervals. 

Divide tbe observations recorded on the record sheet Into sets of 24 consecutive observations. A set Is composed of any 24 consecutive observations. Sets need not be consecutive ln time and-In no case Bhall two 

sets overlap. For each Bet of 24 observations, 

calculate tbe average by summing the opacity 

of the 24 observations and dividing this Bum 

by 24. If on applicable standard specifies an 

averaging time requiring more than 21 observations, calculate the average for all observations made during the specified time 

period. Record the average opacity on a record 

sheet. (See Figure 9-1 for an example.) 

3. Qualifications and testing. 

3.1 Certification requirements. To receive 

certification as a qualified observer, a can--

dldate must bo tested and .demonstrate the 

abiUty to assign opacity readings ln fl percent 

Increments to 25 different black plumes and 

29 different white plumes, with an error 

not to exceod 15 percent opacity on any one 

reading and an average error no t to exceed 

7.5 percent opacity in each category. Candidates ahall be tested according to the procedures described In paragraph 3.3. Smoke 

generators used pursuant to paragraph 3.2 

shall be equipped with a smoke meter which 

meets tho requirements of paragraph 3.3. 

The certification shall be valid for a period 

of Q months, at which time the qualification 

procedure must be repeated by any observer 

tn order to retain certification. _

 r 

" 3.2 Certification procedure. The certification teet consists of showing the candidate a 

complete run of 60 plumes—26 black plumes 

and 25 white plumes—generated by a smoke 

generator. Plumes within each set of 25 black 

and 25 white runs shall be presented In random order. Tbe candidate assigns an opacity 

value to each plume and records his observation on a suitable form. At the completion 

of each run of 60 readings, the score of th e 

candidate ls determined. If a. candidate falls 

to qualify, the complete run of 50 readings 

must be repeated In any retest. The emoke 

test may be administered as part of a smoke 

school or training program, and may be preceded by training or famil lar Ization runs of 

the smoke generator during which candidates 

are shown black and white plumes of known 

opacity. 

- 3.3 Gmoko generator specifications. Any 

smoke generator used for the purposes of 

paragraph 3.2 shall be equipped with t. smoke 

meter Installed to measure opacity across 

the diameter of tbe smoke generator stuck, 

The smoke meter output shall display lnstack opacity based upon a pathlength equal 

to the etack exit diameter, on a full 0 to 100 

percent chart recorder scale. The smoke 

meter optical design and performance shall 

meet the specif cations shown In Table &-1. 

The smoke meter shall be calibrated as prescribed In paragraph 3.3.1 prior to tbe conduct of each smoke reading test. At tho 

completion of each test, the sero and span 

drift ahall be checked and If the drift exceeds -nl percent opacity, the condition shall 

be correoted prio.- to conducting any subsequent teat runs. The smoke meter shall ba 

demanstrated. at Uie time of Installation, to 

meet tbe specifications listed In Table 9-1. 

Thij demonstration shall bo repeated following any subsequent repair or replacement 

of the photocell or associated electronic circuitry Including the chart recorder or output 

meter, or e»ery 6 months, whichever occurs 

first. 

$731 Calibration. Tho emoke meter is 

calibrated after allowing a minimum of 80 

mlnutea warmup by alternately produdng 

simulated opacity of 0 percent and 100 percent. When eOable response at 0 percent or 

100 percent is noted, the smoks meter Is adJusted to produce an output of 0 percent oc 

100 percent, as appropriate. This calibration 

shall be repented until stable 0 percent and 

100 percent readings art. produced without 

adjustment. Simulated 0 percent and 100 

percent opacity values may bo produced by 

alternately switching tbe po-wer to tbe light 

source on and off while the smoke generator 

U not producing smoke. 

B-10 
P.44 

TAB U fr-1—EUOKE fcCFJTER DESIGN ANO 

PStrOBMANCE SPBCinCATI ONS 

Parameter: 

a. Light source 

b. Spectral response 

of photocell. 

c. Angle of view 

d. Angle of projection. 

e. Calibration error. 

f. Zero and span 

• drift. 

g. Response time— 

Specification 

Incoudemsent lamp 

operated at nominal 

rated voltage. 

Pho topic (daylight 

spectral response of 

the human eye— 

reference 4.3). 

15* maximum total 

angle. 

15* maximum total 

angle. 

•±3% opacity, maximum. 

±1 % opacity, 30 

minutes. 

£ 5 seconds. 

3.3,2 Smoke meter evaluation. The 6moke 

meter design and performance are to be 

evaluated as follows: 

3.3.2.1 Light source. Verify from manufacturer's data and from voltage measurements made at the lamp, as Installed, tha t 

the lamp is operated within -±6 percent of 

the nominal rated voltage. 

8.3.2.2 Spectral response of photocell. 

Verily from manufacturer's data tha t Uie 

photocell has a photoplc response; I.e, tbe 

spectral sensitivity of tbe cell Bhall closely 

approximate the standard spectral-luminosity curve for photoplc vision which Is referenced in (b) or Table 0-1. 

3.3.2.3 Angle of view. Check construction 

geoinccty to ensure that the total an^'le of 

view of tbe smoke plume, as reen by the 

photocell, does not exceed 16'. Tbe total 

angle of view may be calculated from: t—2 

tan-1 d/2L, where tf = total angle of view; 

d = the sum of the photocell diameter-f-the 

diameter of the limiting aperture; and 

L = trja distance from the photocell to the 

limiting aperture. Tbe limiting aperture ls 

the point In the path between tbe photocell 

and the smoke plume where tbe angle of 

view la most restricted. In smoke generator 

•moke meter* this Is normally -an orifice 

plate. 

3.3.2.4 Angle of projection. Check construction geometry to ensure tha t tbe total 

angle of projection of tbe lamp on the 

smoke plume does not exceed 16*. The total 

angle of projection may be calculated from: 

6=2 tan- 1 d/2L, where B= total angle of projection; d= the sum of tbe length of tbe 

lamp filament + tbe diameter of tbe limiting 

aperture; and L= the distance from tbe lamp 

to the limiting aperture. 

3.3.2.5 Calibration error. Using neutraldensity filters of known opacity, check the 

error between the actual response and the 

theoretical linear response of the smoke 

meter. This check ls accomplished by first 

calibrating tbe smoke meter according to 

3.3.1 and then Inserttng a series of three 

neutral-density filters of nominal opacity of 

20, 60, and 76 percent In th e Gisoke meter 

pathlength. Filters callbarted within ±3 percent shall be used. Care should be taken 

when Inserting the Alters to prevent stray 

light from affecting the meter. Make a total 

of five nonconsecutlve readings for each 

filter. The maximum error on any one reading shall bo 3 percent opacity. 

3.3.2.8 Zero and span drift. Determine 

the zero and span drift by calibrating and 

operating the smoke generator ln a normal 

manner over a 1-hour period. Tbe drift is 

measured by checking the zero and span at 

the end of this period. 

3.3.2.7 Response time. Determine the response time by producng the series of five 

simulated 0 percent and 100 percent opacity 

values and observing tbe time required to 

reach stable response. Opacity values of 0 

percent and 100 percent may be simulated 

by alternately switching tbe power to the 

light source o2 and on while the smoke 

generator Is not operating. 

4. F.efcrcnccs. 

4.1 Air Pollution Control District Rulta 

and Rtgulations, Los Angeles County Air 

Pollution Control District, Regulation IV, 

Prohibitions, Rule CO. 

4.2 Wslsburd, Melvin L, Field Operations 

and Enforcement Manual for Air, TTJ3. Environmental Protection Agency, Research Triangle Park, N.C, APTD-1100, August 1972. 

pp. 4.1-4 J 6. 

4.3 Condon, E. TJ., and Odisbaw, H., Handboot of Physics, McGraw-Hill Co., N.Y„ N.Y. 

1968, Table 3.1, p. fr-82. 

B-1 1 
FIGURE 9-1 - .. • v 

RECORD OF VISUAL DETERMINATION OF OPACITY " PAGE of 

COMPANY 

LOCATION 

TEST NUMBER, 

DATE 

TYPE FACIL1TY_ 

CONTROL DEVICE 

HOURS OF OBSERVATION. 

OBSERVER 

OBSERVER CERTIFICATION DATE_ 

OBSERVER AFFILIATION 

POINT OF EMISSIONS 

HEIGHT OF DISCHARGE POINT 

i 

H 

i\» 

CLOCK TIME 

OBSERVER LOCATION 

Distance to Discharge 

Direction from Discharge 

Height of Observation Point 

BACKGROUND DESCRIPTION 

WEATHER CONDITIONS 

Hind Direction 

Mind Speed 

Ambient Temperature 

SKY CONDITIONS (clear, 

overcast. % clouds, etc.) 

PLUME DESCRIPTION 

Color 

Distance Visible 

OTHER INFOOttlOH 

Initial 

* 

Final SUMMARY OF AVERAGE OPACITY 

Set 

Number 

; 

Tlmf 

Start—End 

Opac1t\ • . 

Sum Average 

Readings ranged from to % opacity 

The source was/was not In compliance with 

the time evaluation was made. 

.at 

Ol 
FIGURE 9-2 OBSERVATION RECORD PAGE OF 

COMPANY 

LOCATION 

TEST NUMBER" 

DATE 

OBSERVER 

TYPE FACILITY ~ 

POINT OF EMISSION 

Cd 

I 

Hr. Min. 

0 

1 

2 

3 

4 

5 

6 

7 

8 

9 

10 

11 

12 

13 

14 

IS 

16 

17 

IB 

19 

20 

21 

22 

23 

24 

25 

26 

27 

28 

29 

Seconds 

n 15 JU ib 

STEAM PLUME 

(check if applicable) 

Attached Detached COMMENTS 

COMPANY 

LOCATION 

TEST NUMBER 

DATE 

FIGURE 9- 2 OBSERVATION RECORD 

(Continued) 

OBSERVER 

TYPE FACimT 

PAGE OF 

POINT OF EMISSTSN T 

•Hr. Min. 

Seconds 

"D~ 

30 i 

31 

32 

33 

34 

35 

36 

37 

38 

39 

40 

41 

42 

43 

44 

45 

46 

47 

48 

49 

50 

51 

52 

53 

54 

55 

56 

57 

58 

59 

15 

i 

l 

i 

1 

< 

3o 45 

STEAM PLUME 

(check if applicable) 

Attached . Detached COMMENTS 

[FB Doc.74-26160 Filed 11-11-74;3:4S am] 
^ 4 7 

1 TECHNICAL REPORT DATA 

1

 (Please read Instructions on the reverse before completing) 

1. REPORT NO. 2. 

4. TITLE AND SUBTITLE 

Inspectio n Manual for th e Enforcement of 

New Source Performance Standards: Coal 

Preparatio n Plants 

7. AUTHOR(S) 

Yatendra M. Shah and James R. Burke 

9. PERFORMING ORG \NI ZATI ON NAME ANO AOORESS 

PEDCo Environmental, Inc . 

11499 Cheste r Road 

Cincinnati , Ohio 4 524 6 

12. SPONSORING AGENCY NAME AND ADDRESS 

~ .U.S . Environmental Protectio n Agency 

Division of Stationar y Source Enforcement 

Washington, D.C. 20460 

3. RECIPIENT'S ACCESSION NO. 

EPA 340/1-77-022 

5. REPORT DATE 

Date of Issue : August 197!? 

6. PERFORMING ORGANIZATION CODE 

8. PERFORMING ORGANIZATION REPORT NO. 

3210-5-CC, 3270-1-FF 

10. PROGRAM ELEMENT NO. 

1 1 . CONTRACT/GRANT NO. 

68-01-3150 

1 3 . TYPE OF REPORT ANO PERIOD COVERED 

Fina l Report 

14. SPONSORING AGENCY CODE 

-.6. SUPPLEMENTARY NOTES 

DSSE Projec t Officer: Mark Antell 

16. ABSTRACT 

Standards of Performance for new and modified coa l preparatio n 

plants .were promulgated under Section 111 of th e Clean Air Act 

on January 15, 1976. This report presents procedures for in -

spection of coa l preparatio n facilitie s toward determination 

of thei r compliance with NSPS. I t als o provide s background 

information tha t wil l aid th e inspecto r in understanding th e 

coal preparatio n process and the effects of operatin g parameters 

on process emissions. 

17. KEY WORDS ANO DOCUMENT ANALYSIS 

a. DESCRIPTORS 

Air Pollutio n Control 

Coal Preparatio n 

Verificatio n Inspectio n 

Performance Tests 

18. DISTRIBUTION STATEMENT 

Unlimited 

OUS.GOVERNMENTPRINTINGOFFtCE: 1977-260.880:104 

b.lDENTIFIERS/OPEN ENDED TERMS 

New Source Performance Standards 

Enforcement Emission 

Testing 

19. SECURITY CLASS (This Report) 

Unclassifie d 

2 0. SECURITY CLASS (Thispagef 

Unclassifie d 

c. COSATI Field/Croup 

13B 

14D 

2 1 . NO. OF PAGES 

156 

2 2 . PRICE 

f, \ 

EPA Form 2220-1 (t-71)