# Results of the October 18-20, November 14-

15, December 6-7 and 9, 2011 Title V and MACT Particulate Matter Performance Tests at the ArcelorMittal Minorca Mine Inc. Located in Virginia, Minnesota
Primary Crusher Scrubber SV001 Primary Crusher Ore Handling Baghouse SV002 Fine Ore Crusher Scrubber SV008 Fine Ore Drop Baghouse Machine Discharge Scrubber Hearth Layer Bin Scrubber P-3 Baghouse SV009 SV018 SV019 SV022



# MPCA AQD File No. 257 Air Emissions Permit No. 13700062-003 Barr Project No. 23/69-1223.00
Prepared for ArcelorMittal Minorca Mine Inc. Virginia, Minnesota

January 2012

Prepared by Barr Engineering Company 4700 West 77

th 

### Street Minneapolis, MN 55435-4803 Phone: (952) 832-2600 Fax: (952) 832-2601

# Results of the October 18-20, November 14-

15, December 6-7 and 9, 2011 Title V and MACT Particulate Matter Performance Tests at the ArcelorMittal Minorca Mine Inc. Located in Virginia, Minnesota
Primary Crusher Scrubber SV001 Primary Crusher Ore Handling Baghouse SV002 Fine Ore Crusher Scrubber SV008 Fine Ore Drop Baghouse Machine Discharge Scrubber Hearth Layer Bin Scrubber P-3 Baghouse SV009 SV018 SV019 SV022



# MPCA AQD File No. 257 Air Emissions Permit No. 13700062-003 Barr Project No. 23/69-1223.00
Prepared for ArcelorMittal Minorca Mine Inc. Virginia, Minnesota

January 2012

### 3 

# Executive summary

Barr Engineering Company performed particulate matt er emissions tests on seven emission sources, the Primary Crusher scrubber (SV001), Primary Crush er Ore Handling baghouse (SV002), Fine Ore Crusher scrubber (SV008), Fine Ore Drop baghouse (S V009), Machine Discharge scrubber (SV018), Hearth Layer Bin scrubber (SV019), and P-3 baghouse (SV022) at the A rcelorMittal Minorca Mine Inc. located in Virginia, Minnesota. The tests were performed to demonstrate compliance with the facility’s Air Emission Permit and the Taconite MAC T. Control device parametric resets were not performed during this series of tests. Results of the tests are presented in the summary table below.


## Executive Summary Table

Particulate Test Parameter Methods 5,9 and 202 (Pre January 2011) Average Test Results Primary Crusher Scrubber (SV001) Primary

Crusher Ore Handling Baghouse (SV002) Fine Ore

Crusher Scrubber (SV008) Fine Ore

Drop Baghouse (SV009)
Minorca ID 41DC01 41DC02 51DC05 52DC01 Test Date 10/20/2011 10/20/2011 10/19/2011 10/18/20 11 Air Emissions Permit Group -- GP012 GP013 GP003 Control Equipment CE001 CE002 CE008 CE009 MACT/IPER Parametric Limits Reset No No No No Particulate Concentration, gr/dscf Filterable Particulate 0.0025 0.0008 0.0023 0.0013 Filterable Plus Organic Condensibles=TPM 0.0031 0.0014 0.0028 0.0015
Particulate Concentration Limit, gr/dscf 1 0.10 0.08 0.07 0.05 MACT Ore Crushing and Handling Average 1 gr/dscf 3 0.002 Particulate Emission Rate, lb/hr Filterable Particulate 0.13 0.11 0.40 0.50 Filterable Plus Organic Condensibles=TPM 0.15 0.17 0.48 0.59
Particulate Emission Rate Limit, lb/hr

2 57 57 54 55 Visible Emissions, % opacity 4 0 0 0 0

### 4 

## Executive Summary Table (Continued)

Particulate Test Parameter Method 5,9 and 202 (Pre Jan 2011) Average Test Results Machine Discharge Scrubber (SV018) Hearth Layer

Bin Scrubber (SV019) P-3

Baghouse (SV022)
Minorca ID 108DC05 112DC02 114DC01

Test Date 11/15/2011 11/14/2011 12/6,12/7, 12/9/2011 Air Emissions Permit Group GP008 GP014 -- Control Equipment CE018 CE019 CE028 MACT/IPER Parametric Limits Reset No No No Particulate Concentration, gr/dscf Filterable Particulate 0.0016 0.012 0.0001 Filterable Plus Organic Condensibles=TPM 0.0022 0.012 0.0008
Particulate Concentration Limit, gr/dscf 1 0.06 0.10 0.09 MACT Pellet Handling Flow Weighted Average (gr/dscf) 3 0.005 Particulate Emission Rate, lb/hr Dry Catch Only(Filterable) 0.51 0.24 0.01 Filterable Plus Organic Condensibles=TPM 0.70 0.25 0.06
Particulate Emission Rate Limit, lb/hr

2 47 38 67
Visible Emissions,% opacity 4 1 1 0

1 Total particulate (TPM) compliance concentration li mit determined from Minn. Rules 7011.0735 Table 2 for Title V Air Emissions Permit. Determination mad e using the sum of filterable and organic condensib le particulate measured in the stack gas.

2 Total particulate (TPM) compliance emissions limit calculated from Minn. Rules 7011.0730 Table 1 for Title V Air Emissions Permit. Determination made using the sum of filterable and organic condensible particula te measured in the stack gas.

3 In addition to the Minnesota Rules, the source is subject to the Taconite MACT limit of 0.008 gr/dscf filterable particulate matter as the airflow-weight ed average for the Ore Crushing and Handling MACT s ource group. 40 CFR Part 63 Subpart RRRRR Table 1.

4 Opacity limit is 20% opacity, Minn. Rules 7011.071 5 subp. 1(B).

### 14 

# Stack testing procedures and methods

Testing was performed from ports meeting EPA Method 1 criteria. The Method 1 criteria are listed in the table below for each source. Sample port locati on and traverse point detail are provided in Figures 1-14.

Location SV# Distance to

upstream Disturbance (dia.) Distance to

downstream Disturbance (dia.) Number of

ports Number of

Points Average

Absolute Yaw Angle

SV001 10.2 5.1 2 12 4.3 SV002 2.0 1.0 2 24 2.5 SV008 2.0 1.6 2 24 8.9 SV009 3.0 2.1 2 24 2.2 SV018 2.8 8 2 24 0.9 SV019 11 10 2 12 1.2 SV022 4.5 3.0 2 24 0.7



### Volumetric airflow determinations were performed in accordance with EPA Method 2 using an Stype pitot tube. Airflows were determined in conjun ction with the Method 5 tests.

Stack gas compositions used to determine gas molecu lar weight were at ambient concentrations. Stack gas moisture content was determined by the pe rformance of Method 4 in conjunction with the Method 5 performance tests.

Filterable particulate concentrations and emissions rates were determined in accordance with Method 5. Condensible particulate matter concentrations co llected in the back half of the sample train were determined using the pre-January 1, 2011 Method 202 except that hexane was used as the wet catch rinse in place of methylene chloride.

Visible emissions tests were conducted following EP A Method 9. Copies of field data sheets are located in Appendix B. The observer certification for EPA Method 9 is located in Appendix E.

The EPA test methods referenced above are found in 40 CFR part 60, Appendix A, except for Method 202, which is found in 40 CFR Part 51, Appen dix M prior to January 1, 2011.

# TablesArcelorMittal Barr Engineering Co.

Minorca Mine January 20, 2012 Virginia, MN

TABLE 1

PARTICULATE MATTER TEST RESULTS
Primary Crusher Scrubber (SV001)
Parameter Run 1 Run 2 Run 3 Average Scrubber - Pressure Drop, in. H 2 O 2.3 2.3 2.3 2.3 Scrubber - Water Flow Rate, gal/min 52 52 51 52 Test Date 10/20/2011 10/20/2011 10/20/2011 --- Test Period 848 - 1052 1115 - 1319 1357 - 1559 --- Test Duration, min. 120 120 120 120 Avg. Stack Temperature, deg.F 65 66 67 66 Avg. Moisture Content, %V/V 0.7 1.0 1.3 1.0 Particulate Loading, g

Dry Catch 0.0111 0.0150 0.0122 0.0128 Organic Condensibles 0.0033 0.0027 0.0026 0.0029 Aqueous Phase Condensibles 0.0079 0.0047 0.0077 0.0068

Total 0.0190 0.0197 0.0200 0.0195 Air Flow Rate acfm 6,100 6,100 6,100 6,100 scfm 5,900 5,800 5,800 5,800 5,800 5,800 5,800 5,800 dscfm 5,800 5,800 5,800 5,800 Sample Volume acf 79.81 80.40 81.74 80.65 dscf 77.73 77.70 78.47 77.97

Isokinetic Variation, % 97.7 98.2 99.5 98.5

Particulate Concentration, gr/dscf

Dry Catch Only (Filterable) 0.0022 0.0030 0.0024 0.0025 Dry Catch + Organic Condensibles 0.0029 0.0035 0.0029 0.0031 Dry Catch + Organic Condensibles + Aqueous Phase Condensibles 0.0038 0.0039 0.0039 0.0039

Particulate Emissions Rate, lb/hr

Dry Catch Only (Filterable) 0.11 0.15 0.12 0.13 Dry Catch + Organic Condensibles 0.14 0.17 0.14 0.15 Dry Catch + Organic Condensibles + Aqueous Phase Condensibles 0.19 0.19 0.19 0.19

Ore Transfer Rate, LTPH 1522 1524 1747 1598 Total Particulate Emission Rate, lb/LT Ore 0.00012 0. 00013 0.00011 0.00012ArcelorMittal Barr Engineering Co.

Minorca Mine January 20, 2012 Virginia, MN

TABLE 2

PARTICULATE MATTER TEST RESULTS
Primary Crusher Ore Handling Baghouse (SV002)

Parameter Run 1 Run 2 Run 3 Average Baghouse- Pressure Drop, in. H2O 4.6 4.6 4.5 4.6 Baghouse Leak Detector, pA 0.2 0.4 0.3 0.3 Test Duration, min. 120 120 120 120 Avg. Stack Temperature, deg.F 60 62 64 62 Avg. Moisture Content, %V/V 0.3 0.2 0.6 0.3 Particulate Loading, g

Dry Catch 0.0035 0.0042 0.0033 0.0037 Organic Condensibles 0.0022 0.0027 0.0020 0.0023 Aqueous Phase Condensibles 0.0029 0.0027 0.0018 0.0025

Total 0.0085 0.0095 0.0071 0.0084 Air Flow Rate acfm 16,000 16,000 16,000 16,000 scfm 15,000 14,000 15,000 15,000 dscfm 15,000 14,000 15,000 15,000 Sample Volume acf 70.40 69.31 70.66 70.12 dscf 68.49 66.80 67.79 67.69

Isokinetic Variation, % 101.5 102.6 100.1 101.4

Particulate Concentration, gr/dscf

Dry Catch Only (Filterable) 0.00078 0.00097 0.00076 0.00084 Dry Catch + Organic Condensibles 0.0013 0.0016 0.0012 0.0014 Dry Catch Only + Organic Condensibles + 0.0019 0.0022 0.0016 0.0019 Aqueous Phase Condensibles (Total)

Particulate Emissions Rate, lb/hr

Dry Catch Only (Filterable) 0.10 0.12 0.10 0.11 Dry Catch + Organic Condensibles 0.16 0.20 0.16 0.17 Dry Catch + Organic Condensibles + 0.25 0.27 0.21 0.24 Aqueous Phase Condensibles

Ore Transfer Rate, LTPH 1522 1524 1747 1598 Total Particulate Emission Rate, lb/LT Ore 0.0002 0.0 002 0.0001 0.0002ArcelorMittal Barr Engineering Co.

Minorca Mine January 20, 2012 Virginia, MN

TABLE 3

PARTICULATE MATTER TEST RESULTS
Fine Ore Crusher Scrubber (SV008)

Parameter Run 1 Run 2 Run 3 Average Scrubber - Pressure Drop, in. H 2 O 2.3 2.3 2.4 2.3 Scrubber - Water Flow Rate, gal/min 50 48 48 49 Test Date 10/19/2011 10/19/2011 10/19/2011 --- Test Period 1318 - 1531 1611 - 1813 1901 - 2103 --- Test Duration, min. 120 120 120 120 Avg. Stack Temperature, deg.F 56 57 56 56 Avg. Moisture Content, %V/V 1.4 1.0 0.9 1.1 Particulate Loading, g Dry Catch 0.0038 0.0073 0.0161 0.0091

Organic Condensibles 0.0021 0.0016 0.0020 0.0019 Aqueous Phase Condensibles 0.0025 0.0017 0.0021 0.0021

Total 0.0084 0.0105 0.0201 0.0130 Air Flow Rate acfm 21,000 21,000 21,000 21,000 scfm 20,000 20,000 20,000 20,000 dscfm 20,000 20,000 20,000 20,000 Sample Volume acf 61.65 62.73 62.40 62.26 dscf 59.51 60.39 59.40 59.77

Isokinetic Variation, % 100.2 100.7 100.8 100.6

Particulate Concentration, gr/dscf

Dry Catch Only (Filterable) 0.0010 0.0019 0.0042 0.0023 Dry Catch + Organic Condensibles 0.0015 0.0023 0.0047 0.0028 Dry Catch Only + Organic Condensibles + 0.0022 0.0027 0.0052 0.0034 Aqueous Phase Condensibles (Total)

Particulate Emissions Rate, lb/hr

Dry Catch Only (Filterable) 0.17 0.32 0.71 0.40 Dry Catch + Organic Condensibles 0.26 0.39 0.79 0.48 Dry Catch + Organic Condensibles + 0.37 0.46 0.88 0.57 Aqueous Phase Condensibles

Ore Transfer Rate, LTPH 1070 1178 1184 1144 Total Particulate Emission Rate, lb/LT Ore 0.00034 0. 00039 0.00074 0.00049ArcelorMittal Barr Engineering Co.

Minorca Mine January 20, 2012 Virginia, MN

TABLE 4

PARTICULATE MATTER TEST RESULTS
Fine Ore Drop Baghouse (SV009)

Parameter Run 1 Run 2 Run 3 Average Baghouse- Pressure Drop, in. H2O 4.1 4.0 4.2 4.1 Baghouse Leak Detector, pA 160 161 180 167 Test Date 10/18/2011 10/18/2011 10/18/2011 --- Test Period 1200 - 1401 1426 - 1627 1646 - 1847 --- Test Duration, min. 120 120 120 120 Avg. Stack Temperature, deg.F 43 43 43 43 Avg. Moisture Content, %V/V 0.2 0.2 0.3 0.2 Particulate Loading, g Dry Catch 0.0068 0.0094 0.0079 0.0080

Organic Condensibles 0.0014 0.0013 0.0015 0.0014 Aqueous Phase Condensibles 0.0022 0.0014 0.0021 0.0019

Total 0.0104 0.0121 0.0116 0.0114 Air Flow Rate acfm 47,000 47,000 47,000 47,000 scfm 45,000 45,000 45,000 45,000 dscfm 45,000 45,000 45,000 45,000 Sample Volume acf 98.86 100.86 99.68 99.80 dscf 94.34 95.58 94.73 94.88

Isokinetic Variation, % 100.1 100.9 100.2 100.4

Particulate Concentration, gr/dscf

Dry Catch Only (Filterable) 0.0011 0.0015 0.0013 0.0013 Dry Catch + Organic Condensibles 0.0013 0.0017 0.0015 0.0015 Dry Catch Only + Organic Condensibles + 0.0017 0.0020 0.0019 0.0018 Aqueous Phase Condensibles (Total)

Particulate Emissions Rate, lb/hr

Dry Catch Only (Filterable) 0.42 0.58 0.49 0.50 Dry Catch + Organic Condensibles 0.51 0.66 0.59 0.59 Dry Catch + Organic Condensibles + 0.65 0.75 0.72 0.71 Aqueous Phase Condensibles

Ore Transfer Rate, LTPH 1187 1147 1145 1160 Total Particulate Emission Rate, lb/LT Ore 0.00055 0. 00066 0.00063 0.00061ArcelorMittal Barr Engineering Co.

Minorca Mine January 20, 2012 Virginia, MN

TABLE 5

PARTICULATE MATTER TEST RESULTS
Machine Discharge Scrubber (SV018)

Parameter Run 1 Run 2 Run 3 Average Scrubber - - Water Flow Rate, gal/min 565 563 567 565 Scrubber - Fan Amps 27 27 27 27 Test Date 11/15/2011 11/15/2011 11/15/2011 --- Test Period 1055 - 1256 1320 - 1521 1550 - 1751 --- Test Duration, min. 120 120 120 120 Avg. Stack Temperature, deg.F 68 68 68 68 Avg. Moisture Content, %V/V 2.3 2.1 2.0 2.1 Particulate Loading, g

Dry Catch 0.0072 0.0065 0.0106 0.0081 Organic Condensibles 0.0033 0.0022 0.0035 0.0030 Aqueous Phase Condensibles 0.0012 0.0027 0.0058 0.0032

Total 0.0116 0.0114 0.0198 0.0143 Air Flow Rate acfm 41,000 41,000 41,000 41,000 scfm 38,000 38,000 38,000 38,000 dscfm 37,000 37,000 38,000 37,000 Sample Volume acf 83.25 83.78 84.15 83.73 dscf 78.42 78.47 78.96 78.62

Isokinetic Variation, % 99.7 99.3 99.4 99.5

Particulate Concentration, gr/dscf

Dry Catch Only (Filterable) 0.0014 0.0013 0.0021 0.0016 Dry Catch + Organic Condensibles 0.0021 0.0017 0.0027 0.0022 Dry Catch Only + Organic Condensibles + 0.0023 0.0022 0.0039 0.0028 Aqueous Phase Condensibles

Particulate Emissions Rate, lb/hr

Dry Catch Only (Filterable) 0.45 0.41 0.67 0.51 Dry Catch + Organic Condensibles 0.65 0.55 0.88 0.70 Dry Catch + Organic Condensibles + 0.73 0.72 1.25 0.90 Aqueous Phase Condensibles

Pellet Production Rate, LTPH 470 477 476 474 Total Particulate Emission Rate, lb/LT Fired Pellet s 0.0015 0.0015 0.0026 0.0019ArcelorMittal Barr Engineering Co.

Minorca Mine January 20, 2012 Virginia, MN

TABLE 6

PARTICULATE MATTER TEST RESULTS
Hearth Layer Bin Scrubber (SV019)

Parameter Run 1 Run 2 Run 3 Average Scrubber - - Water Flow Rate, gal/min 43 43 42 43 Scrubber - Fan Amps 19 20 20 20 Test Date 11/14/2011 11/14/2011 11/14/2011 --- Test Period 835 - 1036 1101 - 1302 1320 - 1528 --- Test Duration, min. 120 120 120 120 Avg. Stack Temperature, deg.F 56 59 68 61 Avg. Moisture Content, %V/V 1.6 1.8 2.0 1.8 Particulate Loading, g

Dry Catch 0.0315 0.0658 0.0978 0.0651 Organic Condensibles 0.0023 0.0028 0.0028 0.0026 Aqueous Phase Condensibles 0.0019 0.0020 0.0021 0.0020

Total 0.0357 0.0706 0.1028 0.0697 Air Flow Rate acfm 1,800 2,800 3,000 2,500 scfm 1,700 2,600 2,800 2,400 dscfm 1,700 2,600 2,700 2,300 Sample Volume acf 61.79 96.12 101.70 86.54 dscf 58.77 90.28 95.42 81.49

Isokinetic Variation, % 100.4 99.7 99.4 99.8

Particulate Concentration, gr/dscf

Dry Catch Only (Filterable) 0.0083 0.011 0.016 0.012 Dry Catch + Organic Condensibles 0.0089 0.012 0.016 0.012 Dry Catch Only + Organic Condensibles + 0.0094 0.012 0 .017 0.013 Aqueous Phase Condensibles (Total)

Particulate Emissions Rate, lb/hr

Dry Catch Only (Filterable) 0.12 0.25 0.37 0.24 Dry Catch + Organic Condensibles 0.13 0.26 0.38 0.25 Dry Catch + Organic Condensibles + 0.13 0.26 0.39 0.26 Aqueous Phase Condensibles

Pellet Production Rate, LTPH 113 114 113 113 Total Particulate Emission Rate, lb/LT Pellets 0.001 2 0.0023 0.0034 0.0023ArcelorMittal Barr Engineering Co.

Minorca Mine January 20, 2012 Virginia, MN

TABLE 7

PARTICULATE MATTER TEST RESULTS

P-3 Baghouse (SV022)

Parameter Run 1 Run 2 Run 3 Average Baghouse- Pressure Drop, in. H2O 0.9 1.1 1.4 1.1 Baghouse Leak Detector, pA -0.8 4.2 -0.8 0.9 Test Date 12/6/2011 12/7/2011 12/9/2011 --- Test Period 905 - 1102 1113 - 1316 1233 - 1427 --- Test Duration, min. 115 120 111 115 Avg. Stack Temperature, deg.F 33 45 34 37 Avg. Moisture Content, %V/V 0.1 0.7 0.1 0.3 Particulate Loading, g

Dry Catch 0.0003 0.0000 0.0017 0.0007 Organic Condensibles 0.0039 0.0033 0.0031 0.0034 Aqueous Phase Condensibles 0.0025 0.0033 0.0027 0.0028

Total 0.0066 0.0066 0.0074 0.0069 Air Flow Rate acfm 9,100 8,600 7,600 8,400 scfm 9,400 8,500 7,800 8,600 dscfm 9,300 8,500 7,800 8,500 Sample Volume acf 89.02 86.34 71.77 82.38 dscf 87.20 82.64 69.37 79.74

Isokinetic Variation, % 99.5 99.6 98.7 99.3

Particulate Concentration, gr/dscf

Dry Catch Only (Filterable) 0.00005 0.00000 0.00038 0.00014 Dry Catch + Organic Condensibles 0.00073 0.00061 0.0011 0.00080 Dry Catch Only + Organic Condensibles + 0.0012 0.0012 0.0016 0.0014 Aqueous Phase Condensibles (Total)

Particulate Emissions Rate, lb/hr

Dry Catch Only (Filterable) 0.004 0.000 0.025 0.010 Dry Catch + Organic Condensibles 0.059 0.045 0.070 0.058 Dry Catch + Organic Condensibles + 0.09 0.09 0.11 0.10 Aqueous Phase Condensibles

Pellet Transfer Rate, LTPH 4520 4235 4349 4368 Total Particulate Emission Rate, lb/LT Fired Pellet s 0.00002 0.00002 0.00003 0.00002