SOURCE OWNER: Dal Italia

PLANT LOCATION: Muskogee, Oklahoma

SOURCE(S) NAME(S): Wet Scrubber 2

SOURCE(S) CONDITION: Normal Conditions-Tile MACT

SOURCE(S) SHAPE: Circular

TEST PERFORMED: Flow and FTIR

REFERENCE METHOD TESTS: Sample Test Points at Location EPA Method 1

Volumetric Flow and Gas Velocity EPA Method 2

Molecular Weight EPA Method 3 / 3A

Moisture Content EPA Method 4

Hydrogen Chloride EPA Method 320

Hydrogen Fluoride EPA Method 320

ENTEC PROJECT MANAGER (PM) Lynn Beane

ENVIRONMENTAL ANALYST (Team Leader) Erik Groth

ENVIRONMENTAL ANALYST (Assistants) John Drienzo

OWNER'S REPRESENTATIVE(s): Mr. Bob Hurt and Mr. Steve Willis

ENTEC PROJECT NUMBER: 210155

DATES TESTS CONDUCTED: Trav/Prep Run 1 Run 2 Run 3

05/13/10 05/14/10 05/14/10 05/14/10

Thursday Friday Friday Friday

4 5 5 5

Entec Services, Inc.

SOURCE OVERVIEW
Client: Dal Italia Job No. :

Source: Wet Scrubber 2 Input By:

V Port Type Nipple Port Diameter

72

50.0

Inches

80.0 1.11

144.0 2.00 8 8

x' to Force 

More Points?

Point No.

1 2.3 17.3

2 7.6 22.6

3 14.0 29.0

4 23.3 38.3

5 48.7 63.7

6 58.0 73.0

7 64.4 79.4

8 69.7 84.7

* Adjusted points diameter > 24" no point closer than 1.0 inch

* Adjusted points diameter < 24" no point closer than 0.5 inch

Stack Diameters between 12-24 inches minimum points are 8 ; 

4 points per port if the 8 / 2 diameters downstream and

upstream criteria is met.

QC'd by: JRF

 'Before' Flow Disturbance, Distance (B):

Inches

INCHES

72.0 INCHES

INCHES

144.0

80.0

Figure 4-1

Entec Services, Inc

16 D Commerce Ave. Hueytown, AL 35023

STACK DRAWING & TRAVERSE POINT LOCATION

Stack Area, Ft 28.274 2:

210155

Erik Groth

4

Stack Height, feet:

15.00

Inches

Total Number of Traverse Points: 16

Number of Points per port / traverse:

Inside Stack Outside Nipple

 'After' Flow Disturbance, Distance (A):

Stack Diameter, inches:

Stack Properties:

Type of Traverse: Velocity (V) or Particulate (P):

Number of Ports:

Length of Port, inches:

2
Client:

Source:

Traverse Point Delta P Sq. Rt. Delta P Stack Temp. (°F)

1-1 0.0000

1-2 0.0000

1-3 0.0000

1-4 0.0000

1-5 0.0000

1-6 0.0000

1-7 0.0000

1-8 0.0000

2-1 0.0000

2-2 0.0000

2-3 0.0000

2-4 0.0000

2-5 0.0000

2-6 0.0000

2-7 0.0000

2-8 0.0000

 

 

 

 

 

 

 

 

 

Average #DIV/0! 0.0000 #DIV/0!

QC'd by: JRF

Note: Micro-monometer required based on preliminary low flows.

Note: The cyclonic flows were not tested based on the absence of cyclonic flow from previous test results.

Null Reading (Angle)

Preliminary Traverse & Cyclonic Flow Verification

ENTEC Services, Inc.

Test Date:

Run No.:

05/13/10

Preliminary Test

Dal Italia

16 D Commerce Ave, Hueytown, AL 35023

Wet Scrubber 2
Dal Italia

Wet Scrubber 2

1.986

0.987

Deg. R 547.0

Yo = 1.005

10 / (Volume) X SQRT ((0.0319 * (Tm/Pbar))

1.303 X 0.772 QC'd by: JRF

Date:

88.0

Source: Job Number:

Original Y Factor:

210155

87.0

Calibration Date: 9/29/2009

Initial Volume: 87.200

Final Volume: 94.875 Final Meter Temperature:

Initial Meter Temperature:

Average Temperature:

Yo Equation: 

Barometric Pressure: 29.30

Signature: 

Meter Calibration % Difference = -1.87%

86.0

Meter Volume:

Yo Result: 

7.675

ENTEC Services, Inc.

16-D Commerce Ave. Hueytown, Alabama 35023

Initial Meter Box 10 Minute Calibration

Meter Box: NC-2 Original Delta H @:

Client: Location: Muskogee, Oklahoma
Test Run Preliminary

Meter Temperature (estimated based on elevated ambient) 100

Stack Temperature (Preliminary Traverse Average) #DIV/0!

Pitot Tube Correction Factor (calibration or 0.84 for S-Type and 0.99 for Standard pitot) 0.840

Delta H@ (Identified on Meter Box) 1.986

Meter Correction Factor (Identified on Meter Box) 0.987

Molecular Weight of Dry Air 29.400

Average Delta H Desired 2

Average Delta P (Preliminary Traverse Average) #DIV/0!

Percent O2 (Estimate / Preliminary Measurement) 7.00

Percent CO2 (Estimate / Preliminary Measurement) 7.00

Barometric Pressure (Calibrated Barometer) 29.99

Static Pressure at Stack, in. w.g. (Remove +/- Pitot) 0.20

Percent Moisture @ Saturation (if scrubber is saturated) #DIV/0!

% Moisture in Stack Gas (Estimate / Preliminary Meth. 4/ Saturation) 7.00

Suggested Nozzle Diameter/Calculated - Normal #DIV/0!

Nozzle Selected 0.2500

Total Test Time, Minutes 60.0

Required Meter Volume (from industry subpart) 120.0

Calculated Nozzle to Meet Required Volume from subpart #DIV/0!

Estimated Meter Volume for each Test Run #DIV/0!

High Delta P (Based on Preliminary Readings) Keep below highest cal point 0.00

Low Delta P (Based on Preliminary Readings) 0.00

Meter Pressure @ high Delta P #DIV/0!

Meter Pressure @ low Delta P #DIV/0!

K-Factor #DIV/0!

Calculated or linked Data (locked) Black

Linked Data that can be changed (unlocked) Red

Data that needs input values (unlocked) Blue

Molecular weight of Dry Air (30.00) Hidden

Average Delta H (1.00) Hidden

Orifice Flow Rate (0.75) Hidden

Moisture Fraction @ Meter (0.00) Hidden

Molecular Weight @ Meter (29.00) Hidden

Absolute Pressure @ Meter (calculated from preliminary traverse and input data) Hidden

Absolute Pressure @ Stack (calculated from preliminary traverse and input data) Hidden

Velocity, FPS (calculated from preliminary traverse and input data) Hidden

ACFM (calculated from preliminary traverse and input data) Hidden

DSCFM (calculated from preliminary traverse and input data) Hidden

Input Data

Calculated Data

Entec Services, Inc.

K Factor Determination
FTIR Raw Input

Results Summary (from FTIR Output)

See Raw Results from FTIR Data Set

Time (24-hr) Measured Concentration, ppm (wet, v/v)

Run Date Start Run End Run Hydrogen Chloride 

HCl

Hydrogen Fluoride 

HF

1 05/14/10 14:03:00 15:04:00 7.88 8.94

2 05/14/10 15:27:00 16:30:00 12.63 10.55

3 05/14/10 16:55:00 17:58:00 4.98 5.65
Client: 

Source: Wet Scrubber 2

Symbol Units Test Data QC'd by: JRF

- - 1 2 3 AVERAGE

Test Date - - 05/14/10 05/14/10 05/14/10 05/14/10 All Runs

Times, Pollutant Runs (Began - Ended) - Military Time 1403-1504 1527-1630 1655-1758 -

Times, Flow Runs (Began - Ended) - Military Time 1403-1504 1527-1630 1655-1758 1800-1814

Sampling Time  minutes 60.0 60.0 60.0 - 60.0

Stack Area As Ft2 28.27 28.27 28.27 28.27 -

Barometric Pressure Pbar in. Hg 29.79 30.01 30.01 30.01 29.96

Stack Static Pressure Pg in. H20 0.37 0.45 0.45 0.45 0.43

Oxygen Concentration, % (dry basis) O2 % 19.0 19.0 19.0 19.0 19.00

Carbon Dioxide Concentration, % (dry basis) CO2 % 2.0 2.0 2.0 2.0 2.00

Avg. Sq. Rt. of Delta P sqrt P (in. H20)1 / 2 0.702 0.702 0.702 0.702 0.702

Stack Temperature ts

o

F 133.5 133.5 133.5 133.5 133.5

Hydrogen Chloride (FTIR), ppm, wet HCl ppm, wet 7.884 12.634 4.976 8.498

Hydrogen Fluoride (FTIR), ppm, wet HF ppm, wet 8.944 10.555 5.651 8.383

Hydrogen Chloride (FTIR), ppm, dry HCl ppm, d, v / v 9.400 15.103 5.965 10.156

Hydrogen Fluoride (FTIR), ppm, dry HF ppm, d, v / v 10.664 12.618 6.773 10.018

Run Number

Field Data

Data Input By:

210155

Lynn Beane

Dal Italia Job No.:

ENTEC Services, Inc.

16-D Commerce Ave. Hueytown, Alabama 35023

INPUT TEST DATA
Client:

Source: Wet Scrubber 2

Formulas Symbol Units Calculated Data QC'd by: JRF

Run Numbers - - 1 2 3 4 AVERAGE

Test Date(s) - - 05/14/10 05/14/10 05/14/10 05/14/10 3 Runs

Times, Pollutant Runs (Began - Ended) - Military Time 1403-1504 1527-1630 1655-1758 0 -

Times, Flow Runs (Began - Ended) - Military Time 1403-1504 1527-1630 1655-1758 1800-1815

1. Stack Pressure = Pbar + Pg / 13.6 Ps in. Hg 29.82 30.04 30.04 30.04 29.97

2. Meter Pressure = Pbar + H / 13.6 Pm in. Hg 29.79 30.01 30.01 29.94

3. Standard Meter Volume = 17.64* Y* (Vm/Tm)* (Pbar + H / 13.6) Vm(std) dscf 0.000 0.000 0.000 0.00

4a. Standard Volume of Water Vapor Condensed =0.04706*Wimp Vwc(std) scf 0.000 0.000 0.000 0.00

4b. Standard Volume of Water Collected in Silica Gel =0.04715*Wsg Vwsg(std) scf 0.000 0.000 0.000 0.00

5. Moisture Fraction =(Vwc(std) + Vwsg(std))/(Vwc(std) + Vwsg(std) + Vm(std)) Bws fraction 0.1613 0.1635 0.1657 0.1635 0.16

9. Molecular Weight of Stack Gas (dry basis) = 0.32*(O2

)+ 0.44*(CO2)+0.28*(100-(O2)-(CO2)) Md g / g-mole 29.144 29.080 28.992 29.072 29.07

10. Molecular Weight of Stack Gas (wet basis) = Md*(1-Bws)+18.0*(Bws) Ms g / g-mole 27.347 27.268 27.171 27.262 27.26

11. Average Stack Gas Velocity = 85.49*Cp*(sqrt P)avg*SQRT((Ts

) / (Ps*Mw)) vs ft / s 42.89 42.89 42.89 42.89 42.89

12. Stack Gas Flow @ Actual Conditions = 60*vs*As Qa acfm 72,766 72,766 72,766 72,766 72766

13. Stack Gas Flow @ STP = Qa*(Tstd/Ts

)*(Ps/Pstd) Qs scfm 64,971 64,971 64,971 64,971 64971

14. Stack Gas Flow @ STP, dry = Qa*(1-Bws)*(Tstd/Ts

)*(Ps/Pstd) Qstd dscfm 54,349 54,349 54,349 54,349 54349

15. Hydrogen Chloride Conc. @ Std.Conditions =(0.01543*HClmg)/Vm(std) HCl cs gr / dscf 0.00621 0.00998 0.00394 - 0.01

15. Hydrogen Fluoride Conc. @ Std.Conditions =(0.01543*HFmg)/Vm(std) HFcs gr / dscf 0.00387 0.00458 0.00246 - 0.00

21. Hydrogen Chloride Mass Emissions =(60/7000)*HClcs*Qstd HCl lbs/ hr lbs / hr 2.89 4.65 1.84 - 3.13

32. Hydrogen Fluoride Mass Emissions =(60/7000)*HFcs*Qstd HF -lbs / hr lbs / hr 1.80 2.13 1.14 - 1.69

CALCULATED TEST DATA - Metric Units

Formulas Symbol Units Calculated Data QC'd by: JRF

Run Number - - 1 2 3 4 AVERAGE

Test Date - - 05/14/10 05/14/10 05/14/10 05/14/10 3 Runs

Times, Pollutant Runs (Began - Ended) - Military Time 1403-1504 1527-1630 1655-1758 - -

1. Stack Pressure = Ps

*25.4 Ps mm. Hg 757.36 763.09 763.09 763.09 761.66

5. Moisture Fraction =(Vwc(std) + Vwsg(std))/(Vwc(std) + Vwsg(std) + Vm(std)) Bws fraction 0.161 0.163 0.166 0.163 0.163

9. Molecular Weight of Stack Gas, dry basis = 0.32*(O2

)+ 0.44*(CO2)+0.28*(100-(O2)-(CO2)) Md g / g-mole 29.144 29.080 28.992 29.072 29.072

10. Molecular Weight of Stack Gas, wet basis = Md*(1-Bws)+18.0*(Bws) Ms g / g-mole 27.347 27.268 27.171 27.262 27.262

11. Average Stack Gas Velocity = 85.49*Cp*(sqrt P)avg*SQRT((Ts

) / (Ps*Mw)) vs m / s 13.07 13.07 13.07 13.07 13.07

12. Stack Gas Flow @ Actual Conditions = 60*vs

*As Qa acmm 2,061 2,061 2,061 2,061 2,061

13. Stack Gas Flow @ STP = Qa

*(Tstd/Ts)*(Ps/Pstd) Qs scmm 1,840 1,840 1,840 1,840 1,840

14. Stack Gas Flow @ STP (dry) = Qa

*(1-Bws)*(Tstd/Ts)*(Ps/Pstd) Qstd, d dscmm 1,539 1,539 1,539 1,539 1,539

15. Hydrogen Chloride Conc. @ Std.Conditions ( FTIR) =(0.01543*HClmg)/Vm(std) HCl cs mg / dscm 14.217 22.841 9.021 - 15.360

15. Hydrogen Fluoride Conc. @ Std.Conditions (FTIR) =(0.01543*HFmg)/Vm(std) HFcs mg / dscm 8.851 10.473 5.622 - 8.3154

15. Hydrogen Chloride Conc @ 7% O2 =Cs * ((20.9-7)/(20.9-%O2)) c%O2 mg / dscmc 85.92 167.10 59.71 - 104.24

15. Hydrogen Fluoride Conc @ 7% O2 =Cs * ((20.9-7)/(20.9-%O2)) c%O2 mg / dscmc 53.49 76.62 37.21 - 55.77

21. Hydrogen Chloride Mass Emissions =(60/7000)*HClcs*Qstd HCl kg / hr kg / hr 1.3128 2.1091 0.8330 - 1.4183

21. Hydrogen Fluoride Mass Emissions =(60/7000)*HFcs*Qstd HCl kg / hr kg / hr 0.8173 0.9671 0.5191 - 0.7678

Description

Description

Dal Italia Job No.: 210155

Data Input By: Lynn Beane

ENTEC Services, Inc.

16-D Commerce Ave. Hueytown, Alabama 35023

CALCULATED TEST DATA - English Units
Emissions Summary

Test Performed For: Testing Performed By: 

Muskogee, Oklahoma Birmingham Division 

Source(s) Tested: Wet Scrubber 2 Project Manager: 

Test Condition: Normal Conditions-Tile MACT Lynn Beane 

Test(s) Performed:

Run Number 1 2 3 4 Average

Date of Run 5/14/10 5/14/10 5/14/10 5/14/10 3 Runs

Times, Pollutant Runs (Began - Ended) 1403-1504 1527-1630 1655-1758 - -

Times, Flow Runs (Began - Ended) 1403-1504 1527-1630 1655-1758 1800-1814 -

Oxygen Conc., % (dry basis) 19.0 19.0 19.0 19.0 19.0

Carbon Dioxide Conc. % (dry basis) 2.0 2.0 2.0 2.0 2.0

Molecular Weight Of Stack Gas % (dry basis) 29.08 29.08 29.08 29.08 29.07

Molecular Weight Of Stack Gas % (wet basis) 27.27 27.27 27.27 27.27 27.26

Hydrogen Chloride ppm, v / v, d 9.40 15.10 5.96 - 10.16

Hydrogen Fluoride ppm, v / v, d 10.66 12.62 6.77 - 10.02

Stack Temperature o

C 56.4 56.4 56.4 56.4 56.4

Moisture Content %, v / v 16.13 16.35 16.57 16.35 16.35

Average Stack Gas Velocity m / s 13.07 13.07 13.07 13.07 13.07

Stack Gas Flow @ Actual Conditions acmm 2,061 2,061 2,061 2,061 2061

Stack Gas Flow @ STP scmm 1,840 1,840 1,840 1,840 1840

Stack Gas Flow @ Dry Standard Conditions dscmm 1,539 1,539 1,539 1,539 1539

Hydrogen Chloride Conc. @ STP mg / dscm 14.22 22.84 9.02 - 15.36

Hydrogen Fluoride Conc. @ STP mg / dscm 8.85 10.47 5.62 - 8.32

Hydrogen Chloride Conc @ 7% O2 mg / dscmc 85.92 167.10 59.71 - 104.24

Hydrogen Fluoride Conc @ 7% O2 mg / dscmc 53.49 76.62 37.21 - 55.77

Hydrogen Chloride Mass Emissions kg / hr 1.313 2.109 0.833 - 1.418

Hydrogen Fluoride Mass Emissions kg / hr 0.817 0.967 0.519 - 0.768

**Flow testing was performed for this source in conjunction with the Method 29 Testing, Run 2.

Dal Italia

Flows, Moistures, HCl and HF

[NOTE - Run 4 Flow was completed as a Post-ICR flow run to bracket the 3 ICR runs.]

Table 2-6

Note: This page shall only be amended by Tommy Lotz, Jr. or Tom Lotz, Sr.

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Note: Project leaders and Project Mangers please check these items before posting file to server

1

2

3

4

5 Make sure that all unknown inputs are highlighted in yellow

6 Attempt to reduce the amount of yellow/unknowns before turning data in for report writing

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13 Make sure that the correct name of the page input person is on each page

14

15 FTIR Operators see note #43 on Tracking Page tab (to get started)

DoList 11 June 010

Compare Fo to look up table (pass/fail ) diluents

Inputs sheet for ppm from RataMAtion link

Automate rund dates

Add 027 Lab

Add 2F Sheet for 3D Probe

Automate test methods

Clean up and expand metrics, inc temp and pressure

Note: This page shall never be deleted under any circum

Delete unused pages i.e. Square, Run 4, Deionized H2O, or 202 lab when not used in testing.

Remove unnecessary pages - if unsure ask

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data in for report writing

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are hidden. Unhide them as needed.

eference. They are loosely grouped together.
Miller #2 Flue Dimensions (inches) History (r3, JF, 26 Apr 010)

Absorber Stack

Inlet Outlet Paltform

Tests Methods 3A,/6C, 2/4/5B, Size 3A, 6C 3A (bag), 2/4/5B

Stack Height Feet n/a n/a 700

Working height Feet < 75 ~ 175 463

Access Stairs Stairs/Elevator?? Elevator

Flue Shape Rectangle Round Round

Flow Direction Lateral Lateral Vertical

Ports Diameter 4.0 4.0 4.0

Type NPT (cap) Flange Flange

Length (23.5 varies) 41.5 12.0 12.5

Qty. Used 6 4 4

Orientation Floor Down sides/top/bottom Side In

Special 6" for middle

Flue Diameter 372.0 372.0

Length (enter) 792.0

Width (deep) 170.0

Equiv. Diam. 279.9 372.0 372.0

Disturbance Dist A 60.0 720.0 2844.0

A Diameters 0.21 1.94 7.65

Dist B 508.8 84.0 4020.0

B Diameters 1.82 0.23 10.81

Points Qty. Used 30 24 12

Matrix Enter x Deep 6 x 5 6 x 4 4 x 3

Far Point Diatance 153.0 132.4 110.1

Reach 194.5 144.4 122.6

Probe (ft) 16.2 12.0 10.2

Time Run (min) 180 - 180

per Point 6 #VALUE! 15

Data minutes 3 5

Sample Volume dscf 137.7 137.7

acf 153.0 #VALUE! 153.0

Vlc 294.5 484.6

mg 15.1 #VALUE! 19.6

Rate, acfm 0.85 0.85 0.85

Increase Factor 2.6 #VALUE! 2.6

Grain Loading gr/dscf 0.0011 0.0070 .0009 - .0034

DP history 0.554 0.387 0.59 - 0.675

Ts history 288-325 137 132-135

Bws history 0.11 .186 (sat) 15.4-17.3 (sat)

O2 history 6.2-6.8 6.3 6.5 - 6.9

SO2 history 312 1.51 1.1

Pst history 3.0-4.0 -1.3 - -1.65 -0.82

Notes CEMS Probe unheated unheated

Diluents CEMS - bags (4)

SO2 Strats Instrument CEMS CEMS

Time per point 5 6

Qty. Used 30 24

Total time 2.5 2.4

Statics Probes 1 4 (2 of Entec?)

Lines (1/4 poly) 1 @ 100' 200', 150', 2 @ 175'

Runs 1 w/ outlet 1 w/ inlet

Time, min. < 30 < 30

Personnel Sample Deck JC/KK DB/LK

Trailer GC/EG/BB/JF/SO GC/BB/JF/SO JF/BB/SO