Report on the Shredder Baghouse

Air Emissions Test Program

Conducted for Nichols Aluminum Casting

at their Facility Located in Davenport, Iowa

Iowa Plant Number 82-01-089

Report No. 3592-Shredder

November 1, 2012
Nichols Aluminum Casting

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Table of Contents

PROJECT OVERVIEW.............................................................................................................................. 2

General................................................................................................................................................... 2

Methodology........................................................................................................................................... 2

Parameters ............................................................................................................................................. 3

Results .................................................................................................................................................... 3

SUMMARY OF RESULTS ......................................................................................................................... 4

Table 1 – Summary of Particulate Matter Results, Shredder Outlet ...................................................... 4

TEST PROCEDURES.................................................................................................................................. 5

Method Listing........................................................................................................................................ 5

Method 1............................................................................................................................................. 5

Method 2............................................................................................................................................. 5

Method 4............................................................................................................................................. 6

Method 5............................................................................................................................................. 6

Method 9............................................................................................................................................. 7

DESCRIPTION OF PROCESS................................................................................................................... 9

APPENDIX

Figures

Sample Calculations

Parameters

Field Data Printouts

Field Data

Laboratory Data

Calibration Data

Process Data
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Project Overview

General

Airtech Environmental Services Inc. (Airtech) was contracted by Nichols Aluminum 

Casting (Nichols) to perform an air emissions test program at their facility located in 

Davenport, Iowa. The objective of the test program was to satisfy the requirements of 40 

CFR Part 63, Subpart RRR (National Emission Standards for Hazardous Air Pollutants 

for Secondary Aluminum Smelters). Testing in this document was conducted at the 

exhaust of the Shredder baghouse. 

Testing was performed on August 16 and August 17, 2012. Coordinating the field 

portion of the test program were:

Brian McCabe - Nichols Aluminum Casting

Jeff Kaput - Airtech Environmental Services Inc.

Kurt Wepprecht - Airtech Environmental Services Inc.

Methodology

EPA Method 5 was used to determine the emissions of filterable particulate matter (FPM)

at the Shredder baghouse exhaust. A sample of the gas stream was withdrawn 

isokinetically from the exhaust duct and the PM in the sample gas was collected in a glass 

probe and on a glass fiber filter. The weight of particulate collected with the sample train 

combined with the volume of dry gas withdrawn from the stack was used to calculate the 

particulate concentration.

To convert the concentrations of particulate to mass emission rates, the volumetric gas 

flow rate was determined using EPA Methods 1, 2 and 4. In addition, the opacity of the 

emissions at the baghouse exhaust was determined using EPA Method 9. Opacity 

observations were conducted by a certified observer from Airtech.
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Parameters

The following specific parameters were determined at the test location:

• gas velocity

• gas temperature

• moisture content

• filterable particulate matter concentration

• opacity of emissions

Results

A summary of results is presented in Table 1 on page 4. 

Because the test location emitted essentially ambient air, the dry molecular weight of 

29.00 was used in lieu of performing Method 3 as allowed by Method 2, Section 8.6.

Prepared by: Reviewed by:

Cathy Busse Jeff Kaput
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Summary of Results

Table 1 – Summary of Particulate Matter Results, Shredder Outlet

Test Parameters Run 1 Run 2 Run 3 Average

Date 8/16/2012 8/16/2012 8/17/2012

Start Time 14:31 16:00 8:32

Stop Time 15:40 17:09 9:40

Production Rate

Throughput (tons/hr) 43.19 49.93 45.54 46.22

Gas Conditions

Temperature (oF) 104 104 96.9 102

Volumetric Flow Rate (acfm) 73,700 73,600 73,200 73,500

Volumetric Flow Rate (scfm) 67,200 67,000 68,100 67,400

Volumetric Flow Rate (dscfm) 66,200 66,000 67,100 66,500

Moisture (%) 1.44 1.61 1.42 1.49

Particulate Results

Concentration (grains/dscf) 0.0000719 0.000145 0.0000785 0.0000985

Emission Rate (lb/hr) 0.0408 0.0820 0.0452 0.0560

Opacity Results

Average Opacity (%)* 0.00 0.00 0.00 0.00

Minimum Opacity (%) 0 0 0

Maximum Opacity (%) 0 0 0

* The average opacity is based on the highest six-minute reading.
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Test Procedures

Method Listing

The following test methods were referenced for the test program. These methods can be 

found in 40 CFR, part 60, Appendix A.

Method 1 Sample and Velocity Traverse for Stationary Sources

Method 2 Determination of Stack Gas Velocity and Volumetric Flow Rate 

(Type S pitot tube)

Method 4 Determination of Moisture Content in Stack Gases

Method 5 Determination of Particulate Matter Emissions from Stationary 

Sources

Method 9 Visual Determination of the Opacity of Emissions from Stationary 

Sources

Method 1

EPA Method 1 was used to determine the suitability of the test location and to determine 

the sample points used for the particulate and volumetric flow determinations. The test 

location conformed to the minimum requirements of being located at least two diameters 

downstream and at least 0.5 diameters upstream from the nearest flow disturbance.

The Shredder Baghouse exhaust test location was a round, vertical stack with a diameter 

of 45.0 inches. Two ports were sampled with twelve sample points per port. The test 

location was located approximately 3.5 diameters downstream and greater than 3.3

diameters upstream from the nearest flow disturbance. A cross section of the sampling 

location is shown in Figure 1 in the Appendix.

Method 2

EPA Method 2 was used to determine the gas velocity through the test location using a

Type S pitot tube and an incline plane oil manometer. The manometer was leveled and 

“zeroed” prior to each test run. The sample train was leak checked before and after each 

run by pressurizing the positive side, or “high” side, of the pitot tube and creating a 

deflection on the manometer of at least three inches of H2O. The leak check was 

considered valid if the manometer remained stable for 15 seconds. This procedure was 

repeated on the negative side by generating a vacuum of at least three inches of H2O. The 

velocity head pressure and gas temperature were then determined at each point specified 

in Method 1. The static pressure of the duct was measured using a water filled U-tube 

manometer. In addition, the barometric pressure was measured and recorded.

The values measured in Method 2 were used to calculate the volumetric flow rate through 

each test location. The Method 2 sampling apparatus is shown in Figure 2 as part of the 

Method 5 sample train. 
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Method 4

The moisture content at the test location was determined using Method 4. A known 

volume of sample gas was withdrawn from the source and the moisture was condensed 

and measured. The dry standard volume of the sample gas was then compared to the 

volume of moisture collected to determine the moisture content of the sample gas. A 

diagram of the Method 4 apparatus is shown as part of the Method 5 sampling train in

Figure 2 of the Appendix.

To condense the water vapor, the gas sample was passed through a series of 4 impingers. 

The first and second impingers each contained 100 ml of de-ionized ultra filtered water 

(DIUF). The third impinger was empty and the fourth contained a known weight of silica 

gel to absorb any remaining water vapor. Sample train operations followed the 

procedures outlined in EPA Method 5. 

After the test run, the amount of water collected in the condenser system was measured 

gravimetrically. The net weight gain of water was converted to a volume of wet gas and 

then compared to the amount of dry gas sampled to determine the moisture content.

Method 5

EPA Method 5 was used to determine the FPM concentration at the test location. A 

diagram showing the major components of the Method 5 sample train is shown in Figure 

2 of the Appendix. A sample of the gas stream was withdrawn isokinetically from the 

stack and the particulate matter in the sample gas stream was collected in a glass probe 

and on a glass fiber filter. The weight of particulate collected combined with the volume 

of dry gas withdrawn from the stack was used to calculate the particulate concentration. 

To prevent contamination, all components of the sample train were constructed of glass 

with no metal connections. Prior to testing, the components were washed using detergent 

and rinsed with tap water, deionized water and lastly with acetone. After drying, all 

components were sealed with parafilm or Teflon tape.

The sample probe consisted of a glass liner and glass nozzle. Sample gas passed through 

the nozzle and probe assembly and then through a glass fiber filter heated to 250oF (+/-

25o

F). After exiting the filter, the sample gas passed through the condenser system 

described in Method 4. The dry gas exiting the moisture condenser system then passed 

through a sample pump and a dry gas meter to measure the gas volume. After leaving the 

dry gas meter, the sample stream passed through an orifice used to meter the flow rate 

through the sample train. The pressure drop across the orifice was measured with an 

incline plane, oil manometer.

85mm Whatman glass fiber filters were used as the substrate for the particulate sampling. 

The filter was loaded into a glass filter holder with a Teflon support screen that was 

prepared in the same manner as the other components of the sample train. Prior to the 

test run, the filter was desiccated for at least 24 hours and then weighed to the nearest 
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0.0001g until a constant weight was achieved. The weight of the filter was considered 

constant only when two consecutive weights taken at least six hours apart were within 

0.0005g of each other.

The probe was thoroughly pre-cleaned with acetone and the probe wash saved as a quality 

assurance check. The condenser system was then prepared as outlined in Method 4. The 

sample train was leak checked prior to the test run by capping the probe tip and pulling a 

vacuum of at least 15 in. Hg. A leak check was considered valid if the leak rate was less 

than 0.02 cubic feet per minute or four percent of the average sample rate. When not in 

operation in the stack the nozzle was sealed with Teflon tape.

The probe tip was then placed at each of the sample points determined in Method 1. The 

velocity at the sample point was determined using Method 2 by reading the velocity 

pressure from the manometer. Sample gas was withdrawn from the source at a rate such 

that the velocity at the opening of the nozzle matched the velocity of the stack gas at the 

sample point (isokinetically). The gas velocity pressure (∆P), gas meter reading, gas 

meter inlet and outlet temperatures, gas meter orifice pressure (∆H) and pump vacuum 

were recorded for each sample point. 

After the test run, the train was leak checked at the highest vacuum encountered during 

the test run. The condensate net gain of the impinger contents was determined as outlined 

in Method 4 and discarded. The probe liner and nozzle were washed with acetone. The 

rinse was saved in a 250 ml glass jar equipped with a Teflon lined lid. Teflon tape was 

used to seal the filter assembly. The filter was removed from the filter holder and sealed 

in a plastic petri dish once testing was completed.

Analysis of the samples for particulate matter was performed at the Airtech Laboratory in 

Elk Grove Village, Illinois. Each probe rinse was transferred to a tared beaker, 

evaporated to dryness under ambient temperature and pressure conditions, desiccated for 

2 hours and weighed to a constant weight. Each filter was desiccated for 24 hours and 

weighed to a constant weight. The weight-gain of the probe rinse and filter from a test 

run yield the total weight of particulate collected. To eliminate interference in 

establishing a constant weight, both the analytical balance and the desiccators were 

equipped with an ion generating polonium strip designed to eliminate static electricity 

that may have collected on the samples.

Method 9

The opacity of emissions from the test location was determined according to Method 9. 

A certified observer positioned with a line of sight perpendicular to the plume direction 

determined the opacity. The observer viewed the plume with the sun oriented in the 140o

sector of the observer’s back. A minimum distance equal to three times the height of the 

stack was maintained between the observer and the smoke plume. The observer’s line of 

sight did not include more than one plume. 
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Readings were taken at 15-second intervals. Observations were recorded concurrently 

with the particulate testing. Between readings, the observer looked away from the plume 

to rest his eyes. Wind speed and direction were recorded as well as descriptions of the 

plume.
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Description of Process

Nichols Aluminum operates a casting facility on JM Morris Blvd in Davenport Iowa 

(Iowa Plant Number 82-01-089). Testing in this document was conducted on the 

Shredder baghouse. The Shredder baghouse is a Howden HF Dust Filter.