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## MAN.~GEMENT 

# ADMINISTRATION



# SOURCE TESTING REPORT LEIDGH CE:MENT COMPANY

UNION BRIDGE FACILITY UNION BRIDGE, MARYLAND

Testing Dates: August 20 & 

# September 10 through 13, 2002

Prepared for: Lehigh Cement Company

Union Bridge 

# Facility 675 Quaker Hill Road Union Bridge, Maryland 21791

Prepared by: Air/Compliance Consultants, Inc. 1050 William Pitt Way Pittsburgh, Pennsylvania 15238 Project No. 02-046B



# Air/Compliance Consultants,Inc.

# -.

(



# 1. 

# 2. 3. 4.

5. 6. 

# 7. 

# CONTENTS Page INTRODUCTION 1 TESTING PERSONNE-L 1 PROCESS DESCRIPTION 1 TESTIN'G METHODS 2 4.1. TRAVERSE POIN'T SELECTION 2 4.2. GAS VELOCITY 2 4.3. STACK GAS MOLECULAR WEIGHT 2 4.4. STACK GAS MOISTURE CONTENT 2 4.5. DIOXIN AND FUR.AN 

# DETERMINATIONS 3 4.6. PARTICULATE MATIER DETERMINATIONS 3 4.7. OPACITY DETERMINATIONS 3 4.8. CARBON MONOXIDE AND TOTAL HYDROCARBON DETERMINATIONS 4 TESTIN'G LOCATION : 4 TESTIN'G SUMMARY 4 CONCLUSION 5


# TABLES

1. Dioxin and Furan Test Results, Main Kiln Stack, 

# Raw Mill**O~** 

# September 11 & 12, 2002 2. Dioxin and Furan Test Results, Main Kiln Stack, 

# Raw Mill Off, September 10 & 13, 2002 3. Particulate Matter Test Results, Main 

# Kiln Stack, 

# Raw Mill**O~** 

# September 11 & 

# 12, 2002 4. Particulate Matter Test**Resul~,** 

# Main Kiln Stack, 

# Raw Mill Off, September 10 

# & 13,2002 5. Particulate Matter Test Results, Clinker Cooler, August 20,2002 6. Carbon Monoxide and Total Hydrocarbon Test Results,**M~** 

# Kiln Exhaust, September 11,2002 7. Opacity Test Results, Main Kiln Exhaust, September 11,2002 8. Opacity Test Results, Clinker Cooler Exhaust, August 20, 2002
FIGURES 

# 1. Kiln Stack Sampling Diagram 2. Clinker Cooler Exhaust Sampling Diagram

# -,



# l.: CONTENTS CONT.

APPENDICES

A. Testing Protocol B. ComputeriZed & 

# Field Data Sheets C. Plant Process Data D. Laboratory Data E. Equipment Calibrations and Certification Data F. Sample Calculations

# r



# 1. INTRODUCTION SOURCE TESTING REPORT LEIDGH CEMENT COMPANY

UNION BRIDGE FACILITY UNION BRIDGE, MARYLAND

Air/Compliance Consultants, Inc. (ACC!) 

# was contracted by Lehigh Cement Company (Lehigh), to conduct a compliance-testing program on the Main Cement Kiln, and Clinker Cooler exhausts at the facility located in Union Bridge, Maryland. Testing 

# was conducted to comply with the requirements of. the Construction Permit 06-6-0256R, Prevention of Significant Deterioration (PSD) Approval Number PSD-97-01R, New Source Review (NSR) Approval Number NSR-97- 02, and 40 Code ofFederal Regulations (CFR) 63, Subpart LLL requirements.



# 2. TESTING PERSONNEL
( Compliance testing was conducted on August 20, 2002 for the Clinker Cooler exhaust, and September 10 through 13,2002 for the Main 

# Kiln exhaust. ACCI testing personnel consisted of 

# Mr. James Phillippi, Senior Project Manager; 

# Mr. Michael Matvey, Scientist; 

# Mr. William Cowell, Project Engineer; and 

# Mr. Patrick Walters, Technician. 

# Mr. Steve Lang ofthe Maryland Department ofthe Environment (MDEP) observed the testing.



# 3. PROCESS DESCRIPTION
Lehigh operates one Portland Cement Kiln at their Union Bridge facility located in Union Bridge, Maryland. The pyroprocessing system consists of an in-line raw mill and 5-stage preheater 

# kiln system. Limestone (calcium carbonate) is the primary component. The 

# kiln line consists of an in-line raw mill, kiln, clinker cooler, baghouse, stack and associated duct work. The clinker**cool~r** 

# is used to cool the 

# kiln product and exhaust from the clinker cooler is passed through 

# the clinker cooler baghouse then to the cooler exhaust stack. The exhaust from the 

# kiln is fed either through a baghouse to the main 

# kiln stack or taken to heat the raw mill. The exhaust from the mill is then passed through a baghouse to the main 

# kiln stack.

# 4. TESTING METHODS 2

ACCI conducted testing following the United States Environmental Protection Agency (USEPA) Title 40, Part 60, Appendix 

# A, Testing Methods 1 through 5, and 23 at the kiln exhaust. Testing

was also conducted following 40 CFR part 63, subpart LLL and to comply with the requirements of the Construction Permit, NSR Approval, and PSD Approval. All testing was done without deviation from the referenced testing methods and procedures. The approved protocol and relevant correspondence are contained in Appendix A.



# 4.1. Traverse Point Selection
USEPA Method 1 was utilized in the selection oftraverse points for the Main Cement Kiln, and Clinker Cooler stacks. Twenty-four traverse points (twelve per diameter) were utilized to establish gas flow rate for the Clinker Cooler exhaust stack, and twelve traverse points (six per

.diameter) were utilized on the Main Cement Kiln exhaust. Figure 1 presents an illustration of the Main Cement Kiln Stack. Figure 

# 2 presents an illustration ofthe Clinker Cooler Stack.



# 4.2. Gas Velocity
USEPA Method 

# 2 was followed for the detennination ofgas velocity and volumetric flow rate. This procedure utilized S-type Pitot tube and inclined manometer to detennine stack-gas velocity head. Gas 

# temperature measurements were made using a Type K thermocouple and

.c:iigital pyrometer.



# 4.3. Stack Gas**Molecula~** 

# Weight
USEPA Method 3 was utilized for the detel'Dlipation of stack-gas**~olecular** 

# weight. Fyrite gas 

# analyzers were used in the determination of the carbon dioxide (C02) and oxygen (02) /0 

# concentrations. Three grab samples were analyzed for each test run. Nitrogen (N2) was

# {~ determined by the difference.



# 4.4. Stack Gas Moisture Content
USEPA Method 4 describes the procedure that was employed for the determination of the moisture content of the stack gas. The gas moisture was 

# detennined by quantitatively

\\SeIver1lOataIAPROJEC1U.ehigh 

### CemenlIUnlOl1 Bridgo 02oOlSB\RllpClIfslMain Clinkor COoler\ropllft.d&f-partofll8ln.d.cooIlr.doc

# ( 3
condensing stack gas in chilled impingers and a silica gel absorber. The amount of moisture condensed was detennined by the volume ofcondensate collected and weight differential in the silica gel. A calibmted dry gas meter 

# was used to measure the volume of gas sampled. The amount of water condensed and the volume of gas sampled were used to calculate the gas moisture content. Moisture determination was performed concurrently with each test run to 

# allow determination of dry 

# stack-gas molecular weight and to calculate the dry 

# standard cubic feet per minute (OSCFM) flow mte. Moisture sampling was conducted concurrently with the Method 5/23 sampling.



# 4.5. Dioxin and Furan Determinations
USEPA Method 23, "Determination of PolychlorinatedDibenzo-P-Dioxins andPolychlorinated Dibenzofuransfrom Stationary Sources," was used to detennine the dioxin and 

# furan (OIF) emissions. Testing was 

# conducted at two different opemting conditions, with the Raw Mill opemting and Raw Mill not opemting. The traverse points selected in accordance with USEPA Method 1 were isokinetically sampled for 

# three, two hundred forty-minute test runs at each opemting condition. This sample time resulted in an adequate sample volume for accurate mass detenninations. 

# DIF's are extmcted from the sample, separated by high resolution gas chromatogmphy, and measured by high resolution mass spectrometry. 

# DIF testing was conducted on the Main Cement 

# Kiln only. Tables 1 and 2 present the results ofthe 

# DIFtesting.



# 4.6. Particulate Matter Determinations
USEPA Method 5 "Determination of Particulate Emissionsfrom Stationary Sources, " was used to determine the particulate emissions. The USEPA Method 5 sampling tmin 

# was combined with the USEPA Method 23 sampling !min resulting in three, 

# two hundred forty-minute test runs
on the Main Cement 

# Kiln at each of the two opemting conditions. Three 60-minute sampling

runs were conducted on the Clinker Cooler exhaust stack. Tables 3, 4, and 5 present the results ofthe particulate matter (PM) testing.



# 4.7. Opacity Determinations Opacity data 

# was obtained from certified continuous opacity monitors located on the Main 

# Kiln exhaust, and the Clinker Cooler exhaust in approved locations. Three 60-minute data segments

# 4

were obtained in blocks of 6-minute averages. Tables 7 and 8 present the results ofthe opacity monitoring on the Main Kiln**exha~** 

# and Clinker Cooler exhaust, respectively.



# 4.8. Carbon Monoxide and Total Hydrocarbon Determinations
Carbon monoxide (CO) and total hydrocarbon (THC) emissions data were obtained from certified analyzers located on the Main 

# Kiln exhaust stack in 

# an approved location. Three 60- minute data points were obtained and are reported in terms ofpounds per hour (lblhr), in one hour averages. Table 6 presentthe results ofthe CO and THC emissions.



# 5. TESTING LOCATION

Particulate and 

# DIF sampling was perfonned at the outlet ofthe Main Cement Kiln exhaust, after all control equipment. A diagram showing testing locations, stack dimensions, and distances to the nearest upstream. and downstream flow disturbances is included as Figure 1. The traverse and sampling locations on the exhaust stack are installed on the 13.71 foot diameter circular duct. The four sampling ports installed are approximately 295.28 feet downstream (21.5 duct diameters) and 69.55 feet (5.1 duct diameters) upstream. ofthe nearest flow disturbance.

Particulate sampling, and opacity monitoring were also perfonned on the Clinker Cooler exhaust. Figure 2 is a diagram showing testing locations, stack dimensions, and distances to the nearest upstream and downstream flow disturbances. The traverse and sampling locations on exhaust stack are installed on the 11.33 foot diameter circular duct. The four sampling ports installed are approximately 57.4 feet downstream (5.1 duct diameters) and 33.96 feet (3.0 duct diameters) upstream ofthe nearest flow disturbance.



# 6. TESTING SUMMARY

DIFtests results for the 

# kilns are presented in Tables 1 and 2 for Raw Mill On and Raw Mill Off conditions, respectively. Particulate test results are presented in Tables 3, 4, and 5 for the Kiln Raw 

# Mill On, Kiln Raw Mill Off, and the Clinker Cooler, respectively. Appendix B contains the 

# C computerized data sheets and the field data sheets. The test results indicated compliance 

# with the

# (

( \ 

# 5



# Construction Permit and Subpart LLL emission limits. Appendix C contains Lehigh recorded process parameters. These parameters include the 

# kiln operation log, laboratory control sheets, pre-ESP inlet temperature readings, calculations for raw material input, and associate clinker production and documents for data verification. Appendix D contains laboratory analytical data. Appendices E and F contain equipment calibrations, certification data and sample calculations, respectively.



# 7. CONCLUSION

ACCI conducted a compliance testing program on August 20, and September 10 through 13, 2002 for 

# DIF, opacity and PM on the Main Cement 

# Kiln exhaust, and PM and opacity on the Clinker Cooler exhaust at the Lehigh facility located in Union Bridge, Maryland. Main 

# Kiln tests were conducted with the raw mill on and off. All tests were conducted in strict accordance with the applicable USEPA methodologies. Emission rates were shown to be in compliance with the applicable permit limits.

## Table 3. Particulate Matter Test Resulls, Main Kiln Stack, Raw Mill 

## On. SeplembeT II and 12, 2002 

# ( Lehigh Cement Company. Union Bridge, 

## Maryland

Test 

## IhLll Run I**R~2 R~J**  

## A\'erage

Dale Seplemba' II, 2002 September II, 2002 Septembcf 12, 2002 SwtTime 8:02AM 8:46PM 12:S3 PM End Time 8:21 

## PM 12:51 AM 4:58 

## PM Flow Rate (ACFM) 

## 335,320 322,231 352,457 336,669 Flow Roue (SCFM) 256,863 251,794 

## 264,550 257,735 Flow Rale (DSCFM) 220,557 220,838 233,167 225,054 Sample Volume (DSCF) 177.79 172.l8 181.36 177.11 Sample Volume (DSCM) 5.03 4.88 5.14 5.02 Carbon Dioxide (dry volume 

## 'Yo) 25.00 25.00 26.00 25.33 Oxygen (dry volume %) 4.00 4.00 3.00 3.67 Waler Vapor (volume %) 

## 14.13 12.29 11.64 12.69 Stick Temperature (oF) 

## 217.9 

## 205.8 230.6 21S.1 Percent ofIsokinetic Sampling (%) 98.4 95.2 94.7 96.1 Particulale 

## wlo AB Correction 

## (mg) 6.150 6.550 1.750 4.811 AB Correction 

## (mg) 1.659 1.619 

## 20>4 1.777 Particulate 

## with AB Correction 

## (mg) 4.491 4.931 0.350 3.257 

## I>y F«d (IOnsIhour) 393.6 393.6 426.1 404.4 

## I>yF«d (meuie 

## IOnsIbour)111 357.1 357.1 386.5 366.9 

# ( Results

Parliculale Results Emis.sion Concentration (gr2insJDSCF) 0.00039 

## 0.00044**0.ססOO3** 

## 0.00029 Emission Limit (grainslDSCF) 0.01510 Emission Rale (lbIhr) 

## 0.74 0.84 0.06 

## O.H Emission Rate (lbJlon Dry Feed) 0.0019 0.0021 0.0001 0.0014 Emission Rale 

## (kp) 0.33 0.38 

# om 0.25 Emission Rate (kgfMg Dry Feed) (II 

## 0.00094 0.00106**0,ססOO7** 

## 0.00069 Emission Limit (kgfMg 

## Dry Feed) (I) 

## 0.l5



# AB ACFM OSCF DSCFM DSCM SCFM wI. 

## '(I) 1 metric Ion "1000 

## kg'" t Mg. Acetone Blank. 

## Aet\l31 cubic feet 

## per minute Dry Standard 

## cubie feet Dry 

## standard cubic feel 

## per minute Dry standard cubic meIer 

## Standard 

## cubic feet pttminute Wilh (lUI 

# OF kg 

# ''''''' Ibho. Mg 

# m, dryvolwne % Degrees Fahrenheit Kilogram Pounds 

## per hour 

## Pounds per ton Mega.gram Milligram Pe=t 

## b)' Volume, 

## dry ba.sis

IIIIJr.OOI

## AS 

## ACFM DSCF 

# DSCFM DSCM 

# sen1 wlo '(I) 1 rnftrlc: tOD -1000 kg

- 

## J Mg. 

## Acetone 8111lk Actual cubic (eel 

## per minute Dry 

## SWM!.ud cubic feet Dry standard cubic feet per minute 

## Dry 

# standard cubic meter Standard cubic feet per minute With oul 

# OF kg Ibilu lblton 

## Mg 

# mg dry volume 

# % Degrc-es 

## Fahrenheit Kilogram Pound! pel hour 

## Pounds per Ion Megagram Milligram Percent 

# by Volume:, dry 

## basis

11fI5I2OOl

# ( Table 5. Particulate Maller Test Results, Clinker Cooler. August 20, 2002 Lehigh Cemenl Comp3ny, Union Bridge, Maryland



## Test Dati 

## R=1 Run 2 

## Run 3 A\-enge 

# "",**Augu~1** 

## 20, 2002 

## "u&\lS1 20, 2002 Au&USI 20, 2002 

## SwtTime 10:20 AM 

## 11:56AM 1:25 PM End Time 11:30 AM**I:~PM** 

## 2:)) PM flo

.... Rate 

## (ACFM) 

# 195,150 192,IS9 

## 19.1,2&8 

# 193.866 Flow Rate 

## (SCFM) 1S7,7!9 155,173 

## 156,601 156,491 Flow Rate (DSCFM) 154,624 

# 151,862 1S1,827 

## l52,TIl Samp1l: Volume 

# (OSCF) 

# 43.53 44.95 45.53 

## 44.67 Sample Volume (DSCM) 

## 1.23 1.27 

## 1.29 1.27 Carbon Dioxide (dry volumc**~.)** 

# 0.00 0.00 0.00 0.00 O"ygen (dry volume**~.)** 

## 21.00 21.00 

## 21.00 21.00 

## WataVapor (,'olume: %) 

## 1.96 

# 2.13 ].05 

# 2.38 Suck Tempcature (oF) 189.4 190.0 

# 191.2**190~** 

## Percent of lsokinclic Sampling 

## (-4) 

# 93.4 98.2 99.' 97.0 

# Paniculatc wlo 

# AD COlTeclion (mg) 9.450 7.150 

# 7.800 8.133 AD Correction (lOg) 

## 0.106 0.127 

# 0.099 0.111 Particulate \l.ith AD CoJTe'Clion (mg) 9.344 

# 7.023 7.701 

## 8.0n



## "'" F=I (IOnsIbow) 

# 402.3 402.3 

# ..,J

..2.3

"'" F=I (mroic IOnsIOOur)lll 

## 365.0 365.0 

## 365.0 365.0 

# ( Rcsults

PaniClilatc Rcsults ErrUsion Concmtr.ltion (gninsIDSCF) 0.00331 0.(X)241 0.00261 0.0027& Emission Limit (gn;insIDSCF) 0.01290 Emission Rate (lhIhr) 

# 'J' 3.14 

## 3.40 

# 3.64 Emission Rate (Ibllon 

## Dry Feed) 0.0109 

## 0.0078**O.OO~** 

## 0.0091 Emis.sion Ratc (kglht) 

## 1.99 1.42 

## U4 1.65 Emission R<J.te (kglMg Dry Feed) ill 

## 0.00546 0.00390 0.00422 

# o.oom Emis.sion Limit (kg/M8 Dry Feed) tl) 

## 0.15



# AB ACFM DSCF DSCFM DSCM SCfl,i 

# wi.

(1'1 metric too

- 1000 

## kg -I 

## Mg. Acetone Blank Actual cubic fcct 

## per minute Dry standard cubic feet Dry s\:ll1dard cubic feci 

# pet minute Dry sWlCbtd cubic mctn SUndant 

## cubic feet 

## per minule Without 

# ·F kg 

# '''''" Iblton 

## Mg mg 

## dry 

## \"Olwnc ./. Degrecs Fahrenheit Kilognm Pound!; 

# per Itour Potmd5 

# per ton 

## Megagram Milligram PClttllt by 

## VolUl1'll:. 

## dry 

## basis

# r. I



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