Execution of 

Comprehensive 

Performance Test using 

Particulate, HCl and 

Metals Continuous 

Emissions Monitoring 

Systems

Keith Beach, P.E.

Evonik Degussa Corporation

Thomas G. Busmann P.E.

Chris E. McBride, P.E.

Focus Environmental Inc.

Richard H Lambert.

Eli Lilly and Company

Krag Petterson

Cooper Environmental Services
| 

Presentation Overview

History of CEMs Development

CPT Plan and Objectives

CEM Calibrations

CPT Performance Test Results

Conclusions
| 

Sigrist Photometer and Cooper Environmental Services Xact 

Multimetals CEM installed in 2004

Use as Indicators of Compliance 

Required Alternative Monitoring Petition

• Used in conjunction HCL CEMS

• Use of PM, metals, and HCL CEMS in lieu of operational limits

• Regulatory process of AMP approval LONG but successful

• Required major modification to Title V Permit after EPA approval

PM and MetalsCEMS utilized at Tippecanoe 

Laboratories’ Rotary Kiln Incinerator for six years
| 

Sigrist PM CEM
| 

Dual-beam, compensated, 

forward-light attenuation.

Analytes measured in 

unaltered stack gas.

Sampling is super-isokinetic.

Validation using Method 5/5i

Sigrist CTNR CEMS for PM
| 

Modeled on EPA’s proposed 

Performance Specification 10

Produces values every 15 minutes 

for 25 elements of interest

Xact Multi-Metals CEM

Dilution/Dopant

Module

Sampling System

Tape

Control

Module

Control

System

Analysis System

Extraction

System
| 

EXTRACTION MODULE

Removes representative sample from the 

stack gas

Heats and transports sample to stilling 

chamber

Stilling chamber slows down sample 

enabling isokinetic sampling

Sigrist 

Ring Pipe
| 

Xact ANALYSIS MODULE
| 

CPT Plan and Objectives

Objectives

Demonstrate compliance with applicable HWC MACT 

emission limits and operating standards 

Establish incineration system operating limits to ensure 

continuing compliance with the HWC MACT emissions 

and operating standards.

Plan

Conduct the CPT to achieve the same Operating Permit 

Limits as were achieved in the September 2005 CPT 

test. 
Performance 

Evaluation 

Testing for CEMs1

1. Sigrist Particulate CEM

Cooper Environmental Services Xact CEM
| 

Requirements for Calibration Correlation 

for PM CEMS

Acquire PM data at minimum of three separate levels through 

measurement range

Minimum of 12 separate data points

Dual train M5/5i recommended

Correlation of PM CEMS response to reference method values 

• Statistics for use of dual train reference method data

• Statistics for calibration correlation

• Tolerance interval

• Confidence interval

• Correlation Coefficient

• Highest data point acquired during testing is upper limit for use of PM 

CEMS for compliance
| 

2010 ACA Results for the Sigrist

0

5

10

15

20

Method 5 (mg/scm)

0 0.1 0.2 0.3 0.4 0.5

Sigrist (PLA)

Linear Fit

Method 5 (mg/scm) = 1.2031621 + 35.764502*Sigrist (PLA)

RSquare

RSquare Adj

Root Mean Square Error

Mean of Response

Observations (or Sum Wgts)

0.976932

0.975779

0.958086

9.171818

22

Summary of Fit

Model

Error

C. Total

Source

1

20

21

DF

777.50316

18.35857

795.86173

Sum of

Squares

777.503

0.918

Mean Square

847.0193

F Ratio

<.0001*

Prob > F

Analysis of Variance

Intercept

Sigrist (PLA)

Term

1.2031621

35.764502

Estimate

0.341602

1.228869

Std Error

3.52

29.10

t Ratio

0.0021*

<.0001*

Prob>|t|

Parameter Estimates

Linear Fit

Bivariate Fit of Method 5 (mg/scm) By Sigrist (PLA) Year=2010
| 

-5

0

5

10

15

20

25

30

35

Method 5 (mg/scm)

0 0.1 0.2 0.3 0.4 0.5

Sigrist (PLA)

Linear Fit Year=="2006"

Linear Fit Year=="2007"

Linear Fit Year=="2009"

Linear Fit Year=="2010"

Linear Fit Year=="Existing"

Linear Fit

Bivariate Fit of Method 5 (mg/scm) By Sigrist (PLA)

Dashed line is existing equation in Delta V

Orange line is 2010 data

Summary of Sigrist RCAs: 2006 to 2010
| 

Requirements for Calibration Correlation 

for Xact Multi metal CEM

The Quantitative Aerosol Generator (QAG) is a validated 

dynamic spiking technique used to calibrate and audit the 

Xact multi-metals CEMS

•Validated with M301 for quantitative generation of reference metal aerosols

•Used to calibrate and audit Xact Multi-Metals CEMS

•Generates up to 2000 microgram concentrations of MACT metal aerosols

•Uses nebulization of stock solution with droplet size control to provide 

quantitative metal aerosols
| 

Plotted Linear Regression for Chromium

y = 0.9747x + 3.7603

R

2

 = 0.996

0

50

100

150

200

0.00 50.00 100.00 150.00 200.00

Reference Concentration (μg/dscm)

Xact C

oncentration

(μg/dscm)

Plotted Linear Regression for Arsenic

y = 1.0611x + 1.6166

R

2

 = 0.995

0

50

100

150

200

250

0 50 100 150 200

Reference Concentration (μg/dscm)

Xact C

oncentration

(μg/dscm)

Plotted Linear Regression for Cadmium

y = 1.1066x + 2.9945

R

2

 = 0.9912

0

50

100

150

200

250

0.00 50.00 100.00 150.00 200.00

Reference Concentration (μg/dscm)

X

a

ct C

onc

entration

(μg/d

s

c

m)

Plotted Linear Regression for Mercury

y = 1.0219x + 1.843

R

2

 = 0.9941

0

50

100

150

200

0 50 100 150 200

Reference Concentration (μg/dscm)

Xact C

oncentration

(μg/dscm)

Plotted Linear Regression for Lead

y = 1.0387x + 2.2754

R

2

 = 0.9948

0.00

50.00

100.00

150.00

200.00

250.00

0.00 50.00 100.00 150.00 200.00

Reference Concentration (μg/dscm)

Xact C

oncentration

(μg/dscm) Metals RCA Results - 2010
CPT Performance 

Test Results
| 

Particulate Results

1 minute average

20

30

40

Particulate mass 1-minute - P

M

mg/dscm (1-minute uncompressed)

28Sep2010 10:21:45 A

M

28Sep2010 11:13:45 A

M

28Sep2010 12:05:45 P

M

28Sep2010 12:57:45 P

M

29Sep2010 8:03:45 A

M

29Sep2010 8:55:45 A

M

29Sep2010 9:47:45 A

M

29Sep2010 10:39:45 A

M

29Sep2010 11:31:45 A

M

29Sep2010 2:16:45 P

M

29Sep2010 3:08:45 P

M

29Sep2010 4:00:45 P

M

29Sep2010 4:52:45 P

M

29Sep2010 6:05:45 P

M

Sigrist 1 min time

Levey Jennings of Particulate mass 1-minute - PM mg/dscm (1-minute uncompressed)
| 

20

25

30

35

P

articulate

m

ass 15-minute block a

v

era

g

e

m

g/dscm

@

7

%

O

2 (15-minute unco

mpressed)

1 2 3

0

9/2

8/2

010 10:3

0

A

M

0

9/2

8/2

010 11:3

0

A

M

0

9/2

8/2

010 12:3

0

P

M

0

9/2

8/2

010 1:3

0

P

M

0

9/2

9/2

010

8:4

5

A

M

0

9/2

9/2

010

9:4

5

A

M

0

9/2

9/2

010 10:4

5

A

M

0

9/2

9/2

010 11:4

5

A

M

0

9/2

9/2

010

2:3

0

P

M

0

9/2

9/2

010

3:3

0

P

M

0

9/2

9/2

010

4:3

0

P

M

0

9/2

9/2

010

5:3

0

P

M

0

9/2

9/2

010

6:3

0

P

M

MACT Metals 15 Minute data sample end

date/time (triggered and uncompressed)

Individual Measurement of Particulate mass 15-minute block average mg/dscm @ 7% O2 (15-minute uncompressed)

Particulate Results 

15 minute average
| 

-5

0

5

10

15

20

25

30

35

M

A

C

T

M

etals - Hg ug/dscm

@

7

%

O

2 (triggered and unco

mpressed)

1 2 3 3after

0

9/2

8/2

010 11:4

5

A

M

0

9/2

9/2

010

8:3

0

A

M

0

9/2

9/2

010 11:0

0

A

M

0

9/2

9/2

010

3:15

P

M

0

9/2

9/2

010

5:4

5

P

M

MACT Metals 15 Minute data sample end

date/time (triggered and uncompressed)

Levey Jennings of MACT Metals - Hg ug/dscm @ 7% O2 (triggered and uncompressed)

Mercury Result 15 minute average
| 

-2

0

2

4

6

8

10

12

14

M

A

C

T

Metals - LV

M ug/dscm

@ 7%

O2 (triggered and uncompressed)

1 2 3 3after

09/28/2010 11:45 A

M

09/29/2010 8:30 A

M

09/29/2010 11:00 A

M

09/29/2010 3:15 P

M

09/29/2010 5:45 P

M

MACT Metals 15 Minute data sample end

date/time (triggered and uncompressed)

Levey Jennings of MACT Metals - LVM ug/dscm @ 7% O2 (triggered and uncompressed)

LVM Result 15 minute average

Method 29 Beryllium results were non detect (<0.10 ug/dscm @7%O2)
| 

-40

-30

-20

-10

0

10

20

30

40

50

60

70

M

A

C

T

M

etals - S

V

M ug/dscm

@

7

%

O

2 (triggered and unco

mpressed)

1 2 3 3after

0

9/2

8/2

010 11:4

5

A

M

0

9/2

9/2

010

8:3

0

A

M

0

9/2

9/2

010 11:0

0

A

M

0

9/2

9/2

010

3:15

P

M

0

9/2

9/2

010

5:4

5

P

M

MACT Metals 15 Minute data sample end

date/time (triggered and uncompressed)

Levey Jennings of MACT Metals - SVM ug/dscm @ 7% O2 (triggered and uncompressed)

SVM Result 15 minute average
| 

Metals SRE comparision

Metal 2010 (CEMs) 2005 (Method 29)

Total LVM 99.998% 99.998%

Pumpable LVM 99.93% 99.85%

SVM 99.83% 99.74%

Hg 45.70% 17.6%
| 

Summary

•Specific conclusions drawn from the 2010 CPT are as follows:

• PM emission standard was met. A maximum ash feed rate limit can be appropriately 

developed from the T149 CPT results.

• Metal emission standards were met for Hg, SVM, and LVM. Maximum metal feed rates can 

be reliably and appropriately determined using the T149 CPT results.

• Stack gas HCl/Cl2 emission standard was met. A maximum total chlorine feed rate limit can 

be appropriately established from the T149 CPT results.

•Use of CEMs is a viable approach for CPT compliance demonstration.

•For certain incineration facility, a number of benefits can be realized through use of CEMs for 

demonstration of compliance for emissions:

• Improved safety, improved operation efficiency, and economic advantages for waste 

characterization

• Operational flexibility for the incineration system

• Optimization of the establishment of operating parameter limits during the performance of 

the CPT.