# Information Collection Request Boiler MACT E missions Report

We Energies Valley Power Plant Boiler 2 Outlet Duct Milwaukee , Wisconsin March 30 and 31, and April 1, 20101520 Kensington Road, Suite 204 Oak Brook, IL 60523

- 2141 630

- 521

- 940 0 630

- 521

- 9494 fax


# Information Collection Request Boiler MACT E missions Report

We Energies Valley Power Plant Boiler 2 Outlet Duct Milwaukee , Wisconsin March 30 and 31, and April 1, 2010

Report Submittal Date June 2 5 , 2010

Prepared By

Platt Env ironmental Services
Report No. M101302

# Table of Contents

1.0 INTRODUCTION

................................ ................................ ................................ .............................. 1
2.0 EXECUTIVE SUMMAR Y

................................ ................................ ................................ ................. 2
3.0 TEST METHODOLOGY

................................ ................................ ................................ .................. 3 Method 1 Sample and Velocity Traverse Determination

................................ ............................. 3 Method 2 Volumetric Fl ow Rate Determination

................................ ................................ ........... 3 Method 3A Oxygen (O2)/Carbon Dioxide (CO2) Determination

................................ .................. 4 OTM27 Filterable Particulate Determination

................................ ................................ ................ 4 OTM 028 Condensable Particulate Determination

................................ ................................ ...... 4 Method 29 Trace Metals Determination

................................ ................................ ....................... 5 Mercury Determination by Method 30B (Sorbent Trap Method)

................................ .................. 5
4.0 TEST RESULTS SUM MARIES

................................ ................................ ................................ ....... 6
5.0 CONCLUSION A ND CERTIFICATION

................................ ................................ ......................... 10
APPENDIX Test Section Diagram

................................ ................................ ................................ ................. 12 Sample Train Diagrams

................................ ................................ ................................ ............. 14 Calculat ion Nomenclature and Formulas

................................ ................................ ................... 20 Laboratory Sample Analysis

................................ ................................ ................................ ...... 35 Reference Method Tes t Data (Computerized Sheets)

................................ ............................... 65 Ca libration Data

................................ ................................ ................................ ......................... 98 Ga s Certification Sheet

................................ ................................ ................................ ............ 134 Field Data Sheets

................................ ................................ ................................ ..................... 138

### ICR Boiler MACT Emissions Report PES Report No.: M101302 We Energies

- Valley Power Plant Boiler 2 Outlet Duct March 30 and 31, and April 1, 2010



### 1 

# 1.0 Introduction

PLATT ENVIRONME NTAL SERVICES (PES) conducted an information collection request (ICR) b oiler maximum achievable control technology (MACT) emissions test program for We Energies at the Valley Power Plant on the Boiler 2 Outlet Duct on March 30 and 31, and April 1, 2010

. This report summarizes the results of the test program and test methods used.

Test location , test date
, and test parameters are summarized below, in Table 1.



## Table 1
**Test Over view** 

Test Location Test Date Test Method Test Parameter

Boiler 2 Outlet Duct March 30 and 31, and April 1, 2010 USEPA Method 3A Oxygen ( O 2 

### )

, Carbon Dioxide ( CO 2 

### ) Other Test Method 27 (OTM27) <PM2.5 Filterable Particulate, Total Filterable Particulate Other Test Method 28 (OTM 28) Condensable Particulate

USEPA Method 5/ 29 Antimony (Sb), Arsenic (As), Beryllium (Be), Cadmium (Cd), Chromium (Cr), Cobalt (Co), Lead (Pb), Manganese (Mn), Nickel (Ni)

, Selenium (Se) and Filterable Particulate USEPA Method 30B Mercury (Hg)


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



## Table 2
**Test Personnel** 

Location Address Contact Test Facility We Energies Valley Power Plant Milwaukee, Wisconsin M s

. Brenda Berg emann (414) 221

- 2459 (phone) Brenda.bergemann @we

- energies.com Testing Company Representative Platt Environmental Services, Inc. 1520 Kensington Road, Suite 204 Oak Brook, Illinois 60523 Mr. Mark E. Peterson Senior Project Manager (630) 521

- 9400 (phone) mp eterson @plattenv.com



### The test crew consisted of Messrs. J. Aksamitowski, C. Jensen, S. Sands, S. McGough, B. Hendricks, R. Granskog, M. Platt, and M. Peterson of PES. The purpose of the test program was to evaluate the emissions of the constituents liste d i n Table 1 to satisfy the USEPA information request

.

### ICR Boiler MACT Emissions Report PES Report No.: M101302 We Energies

- Valley Power Plant Boiler 2 Outlet Duct March 30 and 31, and April 1, 2010



### 2 

# 2.0 Executive Summary

Selected results of the test program are summarized below, in Table 3. A complete summary of emission test results follows the narrative portion of this report. 

## Table 3
**Test Resul ts** 

Test Location Test Parameter Emission Rate



### Boiler 2 Outlet Duct <PM2.5, filterable, lb/mmBtu 0.0023

> PM 2.5 , filterable, lb/mmBtu 0.0128
PM, condensable 0.0128
<PM2.5, total, lb/mmBtu 0.0151

Total PM, lb/mmBtu 0.027 8 Filterable PM (from M29) 0 .0020
Sb, lb/mmBtu < 1.10 E

- 0 6

As
, lb / mmBtu < 1.10 E

- 0 6

Be
, lb / mmBtu < 2.74 E

- 07

Cd

, lb / mmBtu < 5.62 E

- 07

Cr

, lb/ mmBtu 1.53 E

- 04

Co

, lb / mmBtu < 1.9 5 E

- 06

Pb
, lbs/ mmBtu 2.35 E

- 06

Mn
, lbs/ mmBtu 2.39 E

- 05

Ni
, lb / mmBtu 1.35 E

- 04

Se

, lb / mmB tu < 2. 74 E

- 06 Hg
, lb / mmBtu < 3.92 E

- 07



### A standard F

- Factor of 9780 dscf/mmBtu for Bituminous Coal was used in the calculation of the emissions on a lb/mmBtu basis. Compounds expressed above as less than or equal to values had a fraction or fractions t hat were below detection limits. Detection limits for each fraction were used to determine the emission rate for these compounds.

### ICR Boiler MACT Emissions Report PES Report No.: M101302 We Energies

- Valley Power Plant Boiler 2 Outlet Duct March 30 and 31, and April 1, 2010



### 3 

# 3.0 Test Methodolog y

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



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



## Table 4 **Sample Point Selection**

Test Location Upstream Di stance Downstream D ist ance Test Parameter s Number of Sampling Points

Boiler 2 Outlet Duct > 0.5 > 2.0 Filterable Particulate
, Condensable Particulate, Total Particulate, Sb, As, Be, Cd, Cr, Co, Pb, Mn, Ni, and Se 24

Hg 3



## Method 2 Volumetric Flow Rate Determination Gas ve locity was measured following Method 2, 40 CFR, Part 60, Appendix A, for purposes of calculating stack gas volumetric flow rate. An S

- type pitot tube, differential pressure gauge, thermocouple and temperature readout were used to determine gas velocity at each sample point. All of the equipment used was calibrated in accordance with the specifications of the Method. Calibration data is presented in the Appendix.

### ICR Boiler MACT Emissions Report PES Report No.: M101302 We Energies

- Valley Power Plant Boiler 2 Outlet Duct March 30 and 31, and April 1, 2010



### 4 

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

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

### instrument has a nondispersive infrared

- based detector and operates in a range of 0

- 25%, the CO 2 

### instrument also uses a nodispersive infrared

- based detector and operates in the range of 0

- 20%. All of the equipment used was calibrated in accord ance with the specifications of the Method.



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

### the other greater than PM 2.5


### .



## OTM 028 Condensable Particulate Determination Stack gas condensable particulate concentrations and emission rates were determined in accordance with the dry draft impinger me thod, in conjunction with Method OTM27 filterable pa rticulate sampling. Condensable particulate matter was collected in the impinger portion of the Method OTM027 sampling train.
The condensable particulate matter (CPM) was collected in impingers after filterable particulate mat eri al was collected utilizin g Method OTM27

. The organic and aqueous fractions were then taken to dryness and weighed. The total of all fractions represents the CPM. Compared to the December 17, 1991 promulgated Method 202, this Method includes the addition of a condenser, followed by a water dropout impinger immediately after the final heated filter. One modified Greenburg Smith impinger and an ambient temperature filter follow the water dropout impinger. A schematic of the sampling train configured with these changes is found in the Appendix.
CPM was collected in the water dropout, modified Greenburg Smith impinger and ambient filter portion of the sampling train as described in this Method. The impinger contents were purged with nitrogen (N 2 

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

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

### ). The organic and aqueous fractions were dried and the residues weighed. The total of the aqueo us and organi c fractions represents the CPM. The s amples were analyzed by PES personnel in Des Plaines, Illinois.

### ICR Boiler MACT Emissions Report PES Report No.: M101302 We Energies

- Valley Power Plant Boiler 2 Outlet Duct March 30 and 31, and April 1, 2010



### 5 

## Method 29 Trace Metals Determination Stack gas metals concentrations and emission rates were determined in accordance with Method 29. An Environmental Supp ly Company, Inc. sampling train was used to sample stack gas, in the manner specified in the Method. Analyses of the samples collected were conducted by Maxxam Analytics, Inc

. Samples were analyzed for the following metals, using Inductively Coupled Argon Plasma emission spectroscopy (ICP): Antimony, Arsenic, Beryllium, Cadmium, Chromium, Cobalt, Lead , Manganese, Nickel, and Selenium. All of the equipment used was calibrated in accordance with the specifications of the Method. Calibration data is presented in the Appendix.



## Mercury Determination by Method 30B (Sorbent Trap Method) Paired trains were utilized using three (3) test points at the Boiler 2 Outlet Duct.
Per Method 30B sampling, each sample was collected on the paired in

- situ sorbent traps. A tub e of silica was used to capture remaining moisture prior to the sample reaching the gas metering system.
The sample train used for this test program was designed by APEX, Inc. and meet all requirements for Method 30B sampling. Samples were analyzed onsit e utilizing an Ohio Lumex, Inc. analyzer for total gaseous mercury.

### ICR Boiler MACT Emissions Report PES Report No.: M101302 We Energies

- Valley Power Plant Boiler 2 Outlet Duct March 30 and 31, and April 1, 2010



### 6 

# 4.0 Test Results Summaries

Client: Facility: Test Location: Test Method:

Normal Normal Normal 3/30/10 3/31/10 4/1/10

9:35 8:00 8:10 15:38 14:05 14:17 Run 1 Run 2 Run 3 Average

290.2 290.9 290.9 290.7 8.8% 9.2% 8.2% 8.7% 28.12 27.82 27.82 27.92 124.950 124.116 128.800 125.955 39.450 38.593 39.822 39.288 284,840 278,650 287,524 283,671 171,803 165,479 172,504 169,929

12.8 12.7 12.8 12.8 6.2 6.4 6.3 6.3 97.3 99.5 99.0 98.6

0.0010 0.0007 0.0003 0.0007 0.0017 0.0012 0.0005 0.0011 2.510 1.658 0.779 1.649 0.0034 0.0024 0.0011 0.0023

0.0034 0.0075 0.0005 0.0038 0.0056 0.0127 0.0009 0.0064 8.183 17.959 1.348 9.163 0.0110 0.0255 0.0018 0.0128

0.0053 0.0026 0.0036 0.0038 0.0088 0.0044 0.0059 0.0064 13.002 6.260 8.768 9.343 0.0175 0.0089 0.0119 0.0128

0.0063 0.0033 0.0039 0.0045 0.0105 0.0056 0.0064 0.0075 15.5120 7.9180 9.5470 10.992 0.0209 0.0113 0.0130 0.0151

0.0097 0.0108 0.0044 0.0083 0.0161 0.0183 0.0073 0.0139 23.6950 25.8770 10.8950 20.156 0.0319 0.0368 0.0148 0.0278 Total PM<2.5 grains/acf grains/dscf lb/hr lb/mmBtu (Standard Fd Factor) OTM27/OTM28

grains/dscf Filterable <PM2.5 (OTM27)

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

lb/mmBtu (Standard Fd Factor)

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

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

lb/hr lb/mmBtu (Standard Fd Factor) We Energies Valley Power Plant Boiler 2 Outlet Duct

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

Average Gas Temperature, °F

grains/dscf Stack Conditions End Time

Average %CO 2 by volume, dry basis

Average %O 2 by volume, dry basis

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

Isokinetic Variance

### ICR Boiler MACT Emissions Report PES Report No.: M101302 We Energies

- Valley Power Plant Boiler 2 Outlet Duct March 30 and 31, and April 1, 2010



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

Normal Normal Normal 3/30/10 3/31/10 4/1/10

9:35 8:00 8:10 13:47 12:06 12:22 Run 1 Run 2 Run 3 Average

286.8 286.9 287.4 287.0 10.1% 7.6% 8.1% 8.6%
27.82 27.82 27.82 27.82 126.586 134.833 138.446 133.288 39.908 41.615 42.466 41.330 288,147 300,467 306,614 298,409 170,312 182,451 185,132 179,298

12.8 12.8 12.9 12.8 6.0 6.0 6.2 6.1 101.1 100.6 101.8 101.2

≤ 0.264 ≤ 0.248 ≤ 0.242 ≤ 0.251 ≤ 1.339 ≤ 1.257 ≤ 1.224 ≤ 1.273 ≤ 8.54E-04 ≤ 8.59E-04 ≤ 8.49E-04 ≤ 8.54E-04 ≤ 1.15E-06 ≤ 1.08E-06 ≤ 1.06E-06 ≤ 1.10E-06

≤ 0.430 ≤ 0.403 ≤ 0.393 ≤ 0.409 ≤ 1.339 ≤ 1.257 ≤ 1.224 ≤ 1.273 ≤ 8.54E-04 ≤ 8.59E-04 ≤ 8.49E-04 ≤ 8.54E-04 ≤ 1.15E-06 ≤ 1.08E-06 ≤ 1.06E-06 ≤ 1.10E-06

≤ 0.893 ≤ 0.838 ≤ 0.817 ≤ 0.849 ≤ 0.335 ≤ 0.314 ≤ 0.306 ≤ 0.318 ≤ 2.14E-04 ≤ 2.15E-04 ≤ 2.12E-04 ≤ 2.14E-04 ≤ 2.87E-07 ≤ 2.69E-07 ≤ 2.66E-07 ≤ 2.74E-07

≤ 0.119 ≤ 0.224 ≤ 0.076 ≤ 0.140 ≤ 0.558 ≤ 1.048 ≤ 0.357 ≤ 0.654 ≤ 3.56E-04 ≤ 7.16E-04 ≤ 2.48E-04 ≤ 4.40E-04 ≤ 4.78E-07 ≤ 8.97E-07 ≤ 3.10E-07 ≤ 5.62E-07

65.801 68.920 111.948 82.223 142.337 149.084 242.160 177.860 9.08E-02 1.02E-01 1.68E-01 1.20E-01 1.22E-04 1.28E-04 2.10E-04 1.53E-04

0.743 0.859 ≤ 1.165 ≤ 0.922 1.822 2.106 ≤ 2.857 ≤ 2.262 1.16E-03 1.44E-03 ≤ 1.98E-03 ≤ 1.53E-03 1.56E-06 1.80E-06 ≤ 2.48E-06 ≤ 1.95E-06

0.421 0.305 0.224 0.317 3.629 2.630 1.931 2.730 2.32E-03 1.80E-03 1.34E-03 1.82E-03 3.11E-06 2.25E-06 1.68E-06 2.35E-06

13.132 12.959 10.367 12.153 30.018 29.622 23.697 27.779 1.91E-02 2.02E-02 1.64E-02 1.86E-02 2.57E-05 2.54E-05 2.06E-05 2.39E-05

64.413 70.016 58.770 64.400 157.343 171.029 143.559 157.310 1.00E-01 1.17E-01 9.95E-02 1.06E-01 1.35E-04 1.46E-04 1.25E-04 1.35E-04

≤ 1.019 ≤ 0.957 ≤ 0.932 ≤ 0.969 ≤ 3.348 ≤ 3.143 ≤ 3.061 ≤ 3.184 ≤ 2.14E-03 ≤ 2.15E-03 ≤ 2.12E-03 ≤ 2.14E-03 ≤ 2.87E-06 ≤ 2.69E-06 ≤ 2.66E-06 ≤ 2.74E-06 lb/mmBtu Selenium (Se) Emissions ppb ug/dscm lb/hr lb/hr lb/mmBtu

ppb Chromium (Cr) Emissions

lb/hr lb/mmBtu lb/hr

lb/mmBtu lb/mmBtu

ppb ug/dscm Lead (Pb) Emissions

ppb ug/dscm Nickel (Ni) Emissions lb/hr

lb/hr lb/mmBtu ppb ug/dscm

Manganese (Mn) Emissions ug/dscm

lb/mmBtu

ppb ug/dscm Cobalt (Co) Emissions lb/hr ppb Gas Sample Volume, dscf

Average %O 2 by volume, dry basis

lb/mmBtu ppb Isokinetic Variance Gas Volumetric Flow Rate, dscfm Average %CO 2 by volume, dry basis Average Gas Velocity, ft/sec Gas Volumetric Flow Rate, acfm

ug/dscm ug/dscm

ug/dscm lb/mmBtu

Beryllium (Be) Emissions lb/hr

Cadmium (Cd) Emissions ppb

lb/hr lb/mmBtu Average Flue Pressure, in. Hg Stack Conditions

Flue Gas Moisture, percent by volume

Arsenic (As) Emissions ppb ug/dscm lb/hr Antimony (Sb) Emissions Start Time End Time

Average Gas Temperature, °F

We Energies Valley Power Plant Boiler 2 Outlet Duct

Source Condition 29

Date

### ICR Boiler MACT Emissions Report PES Report No.: M101302 We Energies

- Valley Power Plant Boiler 2 Outlet Duct March 30 and 31, and April 1, 2010



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

Normal Normal Normal 3/30/10 3/31/10 4/1/10

9:35 8:00 8:10 13:47 12:06 12:22 Run 1 Run 2 Run 3 Average

286.8 286.9 287.4 287.0 10.1% 7.6% 8.1% 8.6% 27.82 27.82 27.82 27.82 126.586 134.833 138.446 133.288 39.908 41.615 42.466 41.330 288,147 300,467 306,614 298,409 170,312 182,451 185,132 179,298

12.8 12.8 12.9 12.8 6.0 6.0 6.2 6.1 101.1 100.6 101.8 101.2

0.0004 0.0010 0.0005 0.0006 0.0008 0.0016 0.0008 0.0011 1.103 2.506 1.203 1.604 0.0015 0.0031 0.0015 0.0020 M5 from M29 Sampling Train

grains/dscf

Filterable PM (Method 5)

lb/hr grains/acf

lb/mmBtu (Standard Fd Factor) We Energies Valley Power Plant Boiler 2 Outlet Duct

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

Average Gas Temperature, °F

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

Average %CO 2 by volume, dry basis

Average %O 2 by volume, dry basis

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

Isokinetic Variance

### ICR Boiler MACT Emissions Report PES Report No.: M101302 We Energies

- Valley Power Plant Boiler 2 Outlet Duct March 30 and 31, and April 1, 2010



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

1A 3/30/2010 9:55 11:55 114.055 100.00 1.05E-01 0.88 0.88 7.61E-07

1B 3/30/2010 9:55 11:55 111.962 100.00 1.07E-01 0.89 0.89 7.75E-07

100.00 1.06E-01 0.88 0.89 7.68E-07

2A 3/30/2010 13:00 15:00 109.364 100.00 1.10E-01 0.91 0.91 7.94E-07

2B 3/30/2010 13:00 15:00 108.051 100.00 1.11E-01 0.93 0.93 8.03E-07

100.00 1.10E-01 0.92 0.92 7.99E-07

3A 3/31/2010 8:10 12:10 435.908 100.00 2.75E-02 0.23 0.23 1.99E-07

3B 3/31/2010 8:10 12:10 425.861 100.00 2.81E-02 0.23 0.23 2.04E-07

100.00 2.78E-02 0.23 0.23 2.01E-07

4A 4/1/2010 8:10 12:10 428.677 100.00 2.80E-02 0.23 0.23 2.04E-07

4B 4/1/2010 8:10 12:10 423.163 100.00 2.83E-02 0.24 0.24 2.07E-07

100.00 2.81E-02 0.23 0.24 2.05E-07 100.00 5.40E-02 0.45 0.45 3.92E-07

* Detection Limit Used in calculations due to analytical data below low est point in the calibration curve
**Average of runs 1,3 and 4 due to breakthrough on run 2 Average Average

Overall Average (1, 3 and 4) Average Method 30B (Sorbent Trap) Mercury Test Results Summary We Energies Valley Power Plant Boiler 2 Outlet Duct

Average

### ICR Boiler MACT Emissions Report PES Report No.: M101302 We Energies

- Valley Power Plant Boiler 2 Outlet Duct March 30 and 31, and April 1, 2010



### 10 

# 5.0 Conclusion and Certification

PLATT ENVIRONMENTAL SERVICES is pleased to have been of service to We Energies . If you have any questions regardi ng this test report, please do not hesitate to contact us at 630

- 521

- 9400.



## CERTIFICATION

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

PLATT ENVIRONMENTAL SERVICES

__________________________________ Program Manager Mark E. Peterson

_____________________ _____________ Quality Assurance Jeffrey M. Crivlare

# APPENDIX