EMISSION MEASUREMENT SUMMARY REPORT 

FILTERABLE PARTICULATE MATTER 

FURNACE NO. 12 

FITLERABLE PARTICULATE MATTER 

FURNACE NO. 1 

ERAMET MARIETTA, INC. 

MARIETTA, OHIO

Prepared for: 

Eramet Marietta, Inc. 

P.O. Box 299 

State Route 7 South 

Marietta, Ohio 45750-0299 

EQ PN: 50352.0027 

Prepared by: 

Environmental Quality Management, Inc. 

1800 Carillon Boulevard 

Cincinnati, Ohio 45240 

August 2012 
ii 

CONTENTS 

Section Page 

1. Introduction ...................................................................................................................... 1-1

2. Summary of Test Results ................................................................................................. 2-1

3. Sampling and Analytical Procedures ............................................................................... 3-1

3.1 Location of Measurement Sites .............................................................................. 3-1

3.2 Stack Gas Volumetric Flow Rate............................................................................ 3-1

3.3 Stack Gas Dry Molecular Weight ........................................................................... 3-1

3.4 Stack Gas Moisture Content ................................................................................... 3-2

3.5 Filterable Particulate Matter ................................................................................... 3-2

3.6 Visible Emissions ................................................................................................... 3-2

4. Process Description/Sampling Locations ........................................................................ 4-1

5. Quality Assurance and Quality Control ........................................................................... 5-1

5.1 Field Sampling ........................................................................................................ 5-1

5.2 Calibration Procedures and Frequency ................................................................... 5-1

APPENDICES 

A Calculations

B Raw Field Data

C Analytical Data

D Process Data

E Quality Assurance/Quality Control
iii 

FIGURES 

No. Page 

3-1. EPA Method 5 Sampling Train........................................................................................ 3-3

4-1. Sampling Locations ......................................................................................................... 4-1

TABLES 

No. Page 

1-1. Sampling Locations and Test Parameters ........................................................................ 1-1

2-1. Furnace No. 12 Stack Gas Conditions ............................................................................. 2-3

2-2. Furnace No. 12 Particulate Emissions and Process Operations ....................................... 2-3

2-3. Furnace No. 1 Stack Gas Conditions ............................................................................... 2-4

2-4. Furnace No. 1 Summary of PM Emissions ...................................................................... 2-5

2-5. Furnace No. 1 Process Operations ................................................................................... 2-5

4-1. Sampling Location Parameters ........................................................................................ 4-2

5-1. Field Equipment Calibrations .......................................................................................... 5-2

5-2. Field Checks of Sampling Equipment ............................................................................. 5-2
1-1 

1. INTRODUCTION 

On July 23, 24, and 25, 2012, Environmental Quality Management, Inc. (EQ) personnel 

conducted a compliance air emission program at the Eramet Marietta Inc. (Eramet) facility in 

Marietta, Ohio. Sampling was conducted following the procedures of EPA Reference Methods 1 

through 5, and 9 to quantify emissions of filterable particulate matter from Furnace No. 12 and 

Furnace No. 1. 

EQ utilized EPA Reference Methods 1 and 2 to calculate stack gas velocities and 

temperatures. EPA Method 3 was used to determine the stack gas molecular weight. Moisture, 

filterable particulate matter, and visible emissions were measured following the procedures of 

EPA Methods 4, 5, and 9, respectively. An outline of the specific sampling methods and 

parameters utilized is provided in Table 1-1 and detailed in Section 3. 

Mr. John Hughes of Eramet monitored process operations during testing. Mr. Marco 

Deshaies of the Ohio Environmental Protection Agency (Ohio EPA) observed process operations 

and sampling efforts. Mr. Tom Gerstle of EQ managed the sampling effort. Messrs. Mike Todd, 

Doug Allen, Gary Drexler, Jim Albertz, and Chris Janzen of EQ conducted the emission testing. 

Table 1-1. Sampling Locations and Test Parameters 

Stack I.D. 

Test 

Method Parameter 

No. of 

Samples

Run Time/Sample, 

min 

Furnace No. 12 

Scrubber 

Exhaust 

1-2 

3 

4 

5 

9 

Flow 

CO2/O2

Moisture 

Filterable PM 

Opacity 

3 

3 

3 

3 

1 

60 

60 

60 

60 

60 

Furnace No. 1 

Main and Tap Hole 

Baghouse Exhausts 

1-2 

3 

4 

5 

9 

Flow 

CO2/O2

Moisture 

Filterable PM 

Opacity 

3 

3 

3 

3 

1 

60 

60 

60 

60 

60 
2-1

2. SUMMARY OF TEST RESULTS 

Furnace No. 12 (scrubber exhaust) was sampled on July 25, 2012 to quantify emissions 

of filterable particulate. Furnace No. 12 was sampled at a maximum furnace load, approximately 

20.3 MW. Three 1-hour test runs were conducted at the Furnace No. 12 scrubber exhaust to 

determine the concentration and mass emission rate of filterable particulate matter. Sampling 

was conducted following EPA Reference Methods 1 through 5. 

Furnace No. 1 (2 baghouse exhausts) was sampled on July 23 and 24, 2012 to quantify 

emissions of filterable particulate. The Main Baghouse controls emissions from the furnace and 

the Tap Hole Baghouse controls emissions from the tapping operations. The furnace was 

sampled at a maximum furnace load, approximately 24.1 MW. Three 1-hour test runs were 

conducted at each baghouse. Sampling was conducted following EPA Reference Methods 1 

through 5. 

EPA Reference Method 9, “Visible Determination of the Opacity of Emissions from 

Stationary Sources,” was used to determine opacity from the furnace roof monitor for Furnace 

Nos. 1 and 12. A 1-hour emission observation was completed in conjunction with the particulate 

sampling runs. The opacity averaged 1.6% for the Furnace No. 1 roof monitor with occasional 

5% to 30% opacity observed during tapping. The opacity averaged 4.0% for the Furnace No. 12 

roof monitor with occasional 5% to 25% opacity observed during tapping. 

Table 2-1 summarizes the stack gas conditions measured during each sampling run for 

Furnace No. 12. Stack gas velocity and temperature, volumetric flow rates, gas composition 

(CO2 and O2), and moisture content are detailed for each test run. 

Table 2-2 summarizes the filterable particulate matter and pertinent production data for 

each test run for Furnace No. 12. In addition, a tap was conducted during all the first and second 

test runs. 

Table 2-3 summarizes the stack gas conditions measured during each sampling run for 

Furnace No. 1. Stack gas velocity and temperature, volumetric flow rates, gas composition (CO2

and O2), and moisture content are detailed for each test run. 

Table 2-4 summarizes the filterable particulate matter and pertinent production data for 

each test run for Furnace No. 1. In addition, a tap was conducted during all three test runs. 
2-2

Table 2-5 presents process operations for Furnace No. 1. 

Example calculations are included as Appendix A, raw field data is included as Appendix 

B, analytical data is included in Appendix C, process and visible emissions observation data are 

included in Appendix D, and quality assurance/quality control data are located in Appendix E. 
2-3

Table 2-1. Furnace No. 12 Stack Gas Conditions 

Date: July 25, 2012 Plant: E

Run No. Time 

Stack Gas 

Velocity, 

fpsa

Volumetric Flow Rate 

Temp, °F 

Moisture, 

acfm % CO2, 

b dscfmc

12-1 0800-0906 58.4 173,737 145,610 132 6.2 1.0 12-2 0950-1055 58.7 174,773 144,259 135 7.1 1.0 12-3 1132-1236 58.9 175,207 146,785 132 6.2 1.5 

Average 58.7 174,572 145,551 133 6.5 1.2 

aFeet per second. bActual cubic feet per minute. cDry standard cubic feet per minute. 

Table 2-2. Furnace No. 12 Particulate Emissions and Process Operations 

Date: July 25, 2012 Plant: E

Run No. Time 

Filterable Particulate Matter Process Throughput 

Tons/hr at furnace load 

(MW) 

Pin

Concentration Mass Rate, 

lb/hrc gr/dscfa lb/dscfb

12-1 0800-0906 5.82E-03 8.31E-07 7.26 28.3 at 21.21 MW 53.5 ea12-2 0950-1055 7.19E-03 1.03E-06 8.89 28.3 at 20.86 MW 53.2 ea12-3 1132-1236 7.87E-03 1.12E-06 9.90 28.3 at 18.78 MW 53.3 ea

Average 6.96E-02 9.94E-07 8.68 28.3 at 20.28 MW 53.3 ea

aGrains per dry standard cubic foot. bPounds per dry standard cubic foot. cPounds per hour. 
2-4

Table 2-3. Furnace No. 1 Stack Gas Conditions 

Date: July 23 and 24, 2012 Plant: E

Run No. Time 

Stack Gas 

Velocity, 

fpsa

Volumetric Flow Rate 

Temp, °F 

Moisture, 

acfm % CO2, 

b dscfmc

Furnace No. 1 Main Baghouse MB-5-1 1248-1402 49.9 235,262 173,616 224 3.4 0.0 MB-5-2 1425-1535 51.0 240,425 177,596 223 3.5 0.0 MB-5-3 0800-0908 52.0 244,997 180,934 222 3.1 0.0 

Average 51.0 240,228 177,382 223 3.3 0.0 

Furnace No. 1 Tap Hole Baghouse TB-5-1 1248-1357 56.8 72,372 64,363 116 2.5 0.0 TB-5-2 1425-1535 56.1 71,577 63,523 116 2.7 0.0 TB-5-3 0800-0906 52.5 66,933 59,216 115 2.6 0.0 

Average 55.1 70,294 62,367 116 2.6 0.0 

aFeet per second. bActual cubic feet per minute. cDry standard cubic feet per minute. 
2-5

Table 2-4. Furnace No. 1 Summary of PM Emissions 

Date: July 23 and 24, 2012 Plant: E

Run No. Time 

Filterable Particulate Matter 

Concentration 

gr/dscfa lb/dscfb

Furnace No. 1 Main Baghouse MB-5-1 1248-1402 1.91E-03 2.73E-07 MB-5-2 1425-1635 1.12E-03 1.60E-07 MB-5-3 0800-0908 1.58E-03 2.26E-07 

Average 1.54E-03 2.20E-07 

Furnace No. 1 Tap Hole Baghouse TB-5-1 1248-1357 1.22E-03 1.74E-07 TB-5-2 1425-1535 9.29E-04 1.33E-07 TB-5-3 0800-0906 1.39E-03 1.99E-07 

Average 1.18E-03 1.68E-07 

aGrains per dry standard cubic foot. bPounds per dry standard cubic foot. cPounds per hour. 

Table 2-5. Furnace No. 1 Process Operations 

Date: July 23 and 24, 2012 Plant: E

Run No. Time 

Process Throughput 

Tons/hr at furnace 

load (MW) 

Pressure Drop, inches of wa

Compartments 

1 2 3 4 5 6 

Furnace No. 1 Main Baghouse MB-5-1 1248-1402 17.7 at 25.32 MW 10.51 7.19 6.53 6.48 11.10 10.MB-5-2 1425-1635 17.7 at 23.57 MW 10.34 7.05 6.72 6.74 10.98 10.MB-5-3 0800-0908 17.7 at 23.44 MW 10.43 7.27 6.46 6.94 10.83 10.

Average 17.7 at 24.11 MW 10.67 7.17 6.57 6.72 10.97 10.

Furnace No. 1 Tap Hole Baghouse TB-5-1 1248-1357 17.7 at 25.32 MW 10 TB-5-2 1425-1535 17.7 at 23.57 MW 10 TB-5-3 0800-0906 17.7 at 23.44 MW 10 

Average 17.7 at 24.11 MW 10 
3-1 

3. SAMPLING AND ANALYTICAL PROCEDURES 

The sampling and analytical procedures used in this test program conformed to EPA 

Reference Methods 1 through 5, and 9 as published in the Federal Register. 

3.1 Location of Measurement Sites 

EPA Method 1, “Sample Velocity Traverses for Stationary Sources,” was used to select 

representative measurement sites. Sample locations are discussed in Section 4. Exact 

measurements were verified on site. 

3.2 Stack Gas Volumetric Flow Rate 

EPA Method 2, “Determination of Stack Gas Velocity and Volumetric Flow Rates,” was 

used at each location to determine stack gas volumetric flow rates. Standard and Type “S” pitot 

tubes meeting EPA specifications and an inclined manometer were used to measure velocity 

pressures. A calibrated Type “K” thermocouple attached directly to the pitot tube was used to 

measure stack gas temperature. The stack gas velocity was calculated from the average square 

root of the stack gas velocity pressure, average stack gas temperature, stack gas molecular 

weight, and absolute static pressure. The volumetric flow rate is the product of velocity and 

stack cross-sectional area. 

3.3 Stack Gas Dry Molecular Weight 

EPA Method 3, “Gas Analysis for the Determination of Dry Molecular Weight,” was 

used to determine the stack gas dry molecular weight at all sampling locations. Fyrite analyzer 

readings were conducted for oxygen and carbon dioxide. 
3-2 

3.4 Stack Gas Moisture Content 

EPA Method 4, “Determination of Moisture Content in Stack Gases,” was used to 

determine stack gas moisture content. This method was conducted as part of each particulate 

measurement run. The initial and final contents of all impingers were determined 

gravimetrically. 

3.5 Filterable Particulate Matter 

EPA Method 5, “Determination of Particulate Emissions from Stationary Sources,” was 

used to determine filterable particulate matter. The sampling train consisted of a stainless steel 

nozzle, glass-lined probe, heated glass-fiber filter, and a series of impingers filled with deionized 

water, followed by a vacuum pump, dry gas meter, and calibrated orifice. The probe and filter 

temperatures were maintained at 248o

 ± 25o F. Thermocouples were used to monitor 

temperatures of the stack gas, sample probe, filter, and impinger exit gas. Three 1-hour sampling 

runs were conducted at Furnace No. 12 and Furnace No. 1 baghouse exhausts. Figure 3-1 is a 

schematic of the sampling system. 

3.6 Visible Emissions 

EPA Method 9, “Visual Determination of the Opacity of Emissions from Stationary 

Sources,” was used to measure visible emissions from the building roof monitor. One 60-minute 

test run was conducted at each test site. Opacity readings were recorded every 15 seconds by a 

certified observer. 
3-3

Figure 3-1. EPA Method 5 Sampling Train

Orifice

Thermometers

Thermome

Dry Test

Meter Air-Tight

Pump

Main

Valve

By-Pass

Valve

Vac

Ga

Impingers Ice Ba

Heated

Area

Filter

Holder

Temperature Sensor

Pitot

Manometer

Type “S”

Pitot Tube

Probe
4-1 

4. PROCESS DESCRIPTION/SAMPLING LOCATIONS 

Eramet Marietta, Inc., operates a facility in Marietta, Ohio. The No. 12 Furnace and No. 

1 Furnace were tested at the facility as part of this test program. The No. 12 Furnace, a 

submerged arc furnace, is rated at 22 MW and utilizes two wet scrubbers to control primary and 

secondary emissions. The scrubbers operate simultaneously and exhaust through a single stack. 

The No. 1 Furnace, an electric arc furnace, is rated at 31MW and a maximum production rate of 

35 tons per hour. A Tap Hole Baghouse controls emissions from the furnace tap hole, and a Main 

Baghouse controls emissions from the furnace. 

Table 4-1 presents a summary of the sampling site location. Figure 4-1 is a general 

schematic of the testing locations. 

B

A

C

Direction of

Flow

Figure 4-1. Sampling Locations 
4-2 

Table 4-1. Sampling Location Parameters 

Stack 

Identification 

Stack I.D., 

Inches 

(C) 

Distance from Nearest 

Disturbance 

No. of Sampling 

Points Required, 

Total

Upstream, 

Inches 

(A) 

Downstream, 

Inches 

(B) 

Furnace No. 12 

Scrubber 95.35” >194.0 368.0 24 

Furnace No. 1 

Main Baghouse 120” 480.0” 480.0” 24 

Furnace No. 1 Tap 

Hole Baghouse 60”x51” >190.0 95.0 24 
5-1 

5. QUALITY ASSURANCE AND QUALITY CONTROL 

5.1 Field Sampling 

The field sampling quality assurance for this project included the use of calibrated source 

sampling equipment, reference test methods, and traceability protocols for recording and 

calculating data. The analytical quality assurance included use of validated analytical 

procedures, calibration of analytical instruments, and analysis of control samples and blanks. 

The calibration and quality control procedures used for this test program are described in the 

following subsection, and included in Appendix E of this report. 

5.2 Calibration Procedures and Frequency 

All manual stack gas sampling equipment was calibrated before the test program in 

accordance with the procedures outlined in the Quality Assurance Handbook for Air Pollution 

Measurement Systems, Volume III, EPA-600/4-72-027B. Summarized in Table 5-1 are the stack 

gas sampling equipment calibrations that were performed in preparation for this project. The 

meter boxes were re-calibrated after the test. 

Listed in Table 5-2 are the additional calibration checks that were performed on the 

sampling equipment on site, just prior to the testing, to ensure that equipment was not damaged 

during transport. Calibration checks were conducted before and after each test run. Additional 

calibration information is included in Appendix E of this report. 
5-2 

Table 5-1. Field Equipment Calibrations a

Equipment Calibrated Against Allowable Error 

Method 5 meter box Reference test meter 

Y +0.02 Y 

ΔH@ +0.20 ΔH@ 

post-test 

Y +0.05 Y 

Pitot tube Geometric specifications See EPA Method 2 

Thermocouple ASTM-3F thermometer +1.5% 

Impinger (or condenser 

thermometer) ASTM-3F +2oF 

Dry gas meter 

thermometer ASTM-3F +5o

F 

Probe nozzles Caliper High-low +0.004 in. 

Barometer NBS traceable barometer +0.1 in.Hg 

a

As recommended in the Quality Assurance Handbook for Air Pollution Measurement Systems: Volume III. 

Stationary Source-Specific Methods. EPA-600/4-77-027b, August 1977.

Table 5-2. Field Checks of Sampling Equipment 

Equipment Checked Against Allowable Difference 

Pitot tube Inspection No visible damage 

Thermocouples ASTM 2F or 3F +1.5% 

Probe nozzles Caliper High-low ±0.004 in. 
APPENDIX A 

CALCULATIONS 












APPENDIX B 

RAW FIELD DATA 

























APPENDIX C 

ANALYTICAL DATA 

APPENDIX D 

PROCESS DATA 






APPENDIX E 

QUALITY ASSURANCE/QUALITY CONTROL