Method 321 Testing for HCl at Portland Cement Manufacturing Plants

August 6, 2010
e

concentr

illion vo

 are below

 the dete

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Exhaust Stream %Moisture 0 0768 0 0857 0 0765 %Worksheet Title: HCl Emission Test Results Template Using Method 321Who Should Complete this Spreadsheet? Facilities that use Method 321 to test for HClCompany Name: Lehigh Southwest Cement CompanyFacility Name: TehachapiAddress: 13578 Tehachapi BlvdCity: TehachapiState: CAKiln ID:Kiln Type: PH/PCIn-line Raw Mill: YESControl Device Configuration: Baghouse

Parameter

ple #1 Sampl ple #2 ple #3

Samp

l

Sampl

erageUnits 

Test Av

Enter HCl parts per mtest resultsplease note(e.g., [< 0.0

ation value in dry 

lume (ppmvd). If the 

 detection limit, 

ction limit in brackets 

Select appropriate unit from list. If other is selected please describe units in column H at right. 

Sample Date (mm/dd/yyyy) 3/25/2010 3/27/2010 3/27/2010HCl Concentration - as measured - dry basis 2.83 2.31 0.88 ppmvd 

Oxygen Concentration - dry basis 13.38 11.77 11.97 %

CO2 Concentration - dry basis 13.96 16.47 15.84 %

HCl Concentration - corrected to 7% oxygen 5.24 3.52 1.36 3.37 ppmvd @ 7% O2 

Exhaust Stream %Moisture 0.0768 0.0857 0.0765 %Exhaust Flowrate 168536 177917 166377 dscfmExhaust Temperature 157.2 165.5 160.4 FSample Date (mm/dd/yyyy) 3/25/2010 3/25/2010
HCl Concentration - as measured - dry basis 0.91 0.62 ppmvd 

Oxygen Concentration - dry basis 12.62 13.28 %

CO2 Concentration - dry basis 15.06 13.96 %

HCl Concentration - corrected to 7% oxygen 1.53 1.13 1.33 ppmvd @ 7% O2 

Exhaust Stream %Moisture 0.0264 0.0311 %

Exhaust Flowrate 178441 167033 dscfm

Exhaust Temperature 278.5 277.4 F

Notes:Peach shaded cells indicate areas where the user will enter a responseOnly two (2) runs were completed during Raw Mill Off condition due to numerousFTIR monitor and process problems.
Mill On

Test Location Note

Indicate whether the test occurred upstream or downstream of a control device(s); list the control device(s)

If kiln has an in-line raw mill, indicate raw mill status during tests (i.e., raw mill on or raw mill off). Provide any other information supporting information you think is necessary about this test report. 

Downstream; Baghouse Mill On

Mill OnMill OnMill On
Downstream; Baghouse Mill Off

Mill OffMill OffMill Off
Parameter ###gUnits 

ncentrati

olume (p

low dete

ction lim

0]). 

HCl d 7% d @ Worksheet Title: HCl Emission Test Results Template Using Method 321Who Should Complete this Spreadsheet? Facilities that use Method 321 to test for HClCompany Name: Lehigh Southwest Cement CompanyFacility Name: ReddingAddress: 15390 Wonderland BlvdCity: ReddingState: CAKiln ID: 1Kiln Type: PHIn-line Raw Mill: YesControl Device Configuration: In line Raw Mill/Kiln Baghouse (S260)

Parameter #1 Sample 2 Sample #3 Sample e Test AveraUnits

Enter HCl coper million vresults are benote the dete(e.g., [< 0.01

on value in dry parts 

pmvd). If the test 

ction limit, please 

it in brackets 

Select appropriate unit from list. If other is selected please describe units in column H at right. 

Sample Date (mm/dd/yyyy) 3/16/2010 3/16/2010 3/16/2010HCl Concentration - as measured - dry basis 3.00 1.67 1.60 ppmvd 

Oxygen Concentration - dry basis 11.07 10.72 11.60 %

CO2 Concentration - dry basis 16.62 17.18 15.92 %

HCl Concentration oncentration - corrected to ox 7%ygen 4 2.4 2 2.9 2 3.9 2 9.7 ppmvd @ 7% O2 Exhaust Stream %Moisture 14.0 15.3 15.5 %

Exhaust Flowrate 133,025 135,639 133,951 dscfm

Exhaust Temperature 228.4 227.9 218.0 degrees F
Sample Date (mm/dd/yyyy) 3/17/2010 3/17/2010 3/17/2010

HCl Concentration - as measured - dry basis 35.29 16.98 15.91 ppmvd 

Oxygen Concentration - dry basis 9.236 8.914 8.966 %

CO2 Concentration - dry basis 19.74 20.16 20.29 %

HCl Concentration 42.05 19.69 18.53 26.76 ppmvd @ 7% O2 

Exhaust Stream %Moisture 14.8 14.5 5.5 %

Exhaust Flowrate 115,358 111,530 108,519 dscfm

Exhaust Temperature 280.0 281.7 284.3 degrees F

Notes:Peach shaded cells indicate areas where the user will enter a response
Test Note

ous

Test Location Location

Indicate whether the test occurred upstream or downstream of a control device(s); list the control device(s)

If kiln has an in-line raw mill, indicate raw mill status during tests (i.e., raw mill on or raw mill off). Provide any other information supporting information you think is necessary about this test report. 

Downstream; Downstream; Baghouse agh Raw mill on

Raw mill onRaw mill onRaw mill on
Downstream; Baghouse Raw mill off

Raw mill offRaw mill offRaw mill off
Parameter ###gUnits 

ncentrati

olume (p

elow dete

ction lim

0]). 

HCl d 7% d @ Worksheet Title: HCl Emission Test Results Template Using Method 321Who Should Complete this Spreadsheet? Facilities that use Method 321 to test for HClCompany Name: Lafarge North AmericaFacility Name: Ravena Cement PlantAddress: 1916 Route 9W, PO Box 3City: RavenaState: New YorkKiln ID: Kiln 1Kiln Type: WetIn-line Raw Mill: NoControl Device Configuration: Electrostatic Precipitators

Parameter #1 Sample 2 Sample #3 Sample e Test Units

 Avera

Enter HCl coper million vresults are bnote the dete(e.g., [< 0.01

on value in dry parts 

pmvd). If the test 

ction limit, please 

it in brackets 

Select appropriate unit from list. If other is selected please describe units in column H at right. 

Sample Date (mm/dd/yyyy) 3/12/2010 3/12/2010 3/12/2010HCl Concentration - as measured - dry basis 30.2 26.9 33.5 ppmvd Oxygen Concentration - dry basis 4.9 4.9 4.9 %CO2 Concentration - dry basis 18.6 18.3 17.9 %

HCl Concentration oncentration - corrected to 7% oxygen 26.2 23.4 29.1 2 ppmvd @ 7% O2 

6.2 ppmv 7% O2 

Exhaust Stream %Moisture 26.4 25.2 24.7 %Exhaust Flowrate 577,108 575,859 590,980 acfmExhaust Temperature 261,756 263,979 272,533 dscfm
Notes:

Oxygen measurements were conducted at two locations - in the stackwhere the volumetric flow rate testing was conducted and in thebreaching, where the HCl testing was conducted. Oxygen data collected at the breaching location were used to correct HCl data to 7% O2. See report text for further details
Test Location Location Note

Indicate whether the test occurred upstream or downstream of a control device(s); list the control device(s)

If kiln has an in-line raw mill, indicate raw mill status during tests (i.e., raw mill on or raw mill off). Provide any other information supporting information you think is necessary about this test report. 

Downstream Downstream NA

Samples collected in stack breaching. See report text for details.
oncentrat

llion volu

re below

the detec

0]). 

Worksheet Title: HCl Emission Test Results Template Using Method 321Who Should Complete this Spreadsheet? Facilities that use Method 321 to test for HClCompany Name: Lafarge North AmericaFacility Name: AlpenaAddress: 1435 Ford AvenueCity: AlpenaState: MichiganKiln ID: K23Kiln Type: Long DryIn-line Raw Mill: NoControl Device Configuration: Fabric Filter

Parameter

Sample #1

Sample #2

Sample #3

Test 

AverageUnits

Units 

Enter HCl cparts per mitest results aplease note (e.g., [< 0.01

ion value in dry 

me (ppmvd). If the 

 detection limit, 

tion limit in brackets 

Select appropriate unit from list. If other is selected please describe units in column H at right. 

Sample Date (mm/dd/yyyy) 3/25/2010 3/25/2010 3/25/2010

HCl Concentration - as measured - dry basis

34.84 33.79 29.55

ppmvd 

Oxygen Concentration - dry basis 6.22 5.96 6.18 % (dry)

CO2 Concentration - dry basis 23.35 23.63 23.24 % (dry)

HCl Concentration - corrected to 7% oxygen

32.99 31.43 27.91 30.78

ppmvd @ 7% O2 

Exhaust Stream %Moisture 5.87 5.56 5.25 %

Exhaust Flowrate 146090 144187 145502 SCFM

Exhaust Temperature ~ 400 ~ 400 ~ 400 degrees F

Sample Date (mm/dd/yyyy)

HCl Concentration - as measured - dry basis

N/A N/

d

A N/A

ppmvd 

Oxygen Concentration - dry basis N/A N/A N/A %

CO2 Concentration - dry basis N/A N/A N/A %
HCl Concentration N/A N/A N/A ppmvd @ 7% O2

Exhaust Stream %Moisture N/A N/A N/A %Exhaust Flowrate N/A N/A N/A (select flowrate units)

Exhaust Temperature N/A N/A N/A (select temperature units)Notes:Peach shaded cells indicate areas where the user will enter a response
Test Location Note

Indicate whether the test occurred upstream or downstream of a control device(s); list the control device(s)

If kiln has an in-line raw mill, indicate raw mill status during tests (i.e., raw mill on or raw mill off). Provide any other information supporting information you think is necessary about this test report. 

Downstream

NA

Based on preliminary Velocity Traverse on 3/24/2010

oncentrat

llion volu

re below

the detec

0]). 

Worksheet Title: HCl Emission Test Results Template Using Method 321Who Should Complete this Spreadsheet? Facilities that use Method 321 to test for HClCompany Name: Lafarge North AmericaFacility Name: AlpenaAddress: 1435 Ford AvenueCity: AlpenaState: MichiganKiln ID: K23Kiln Type: Long DryIn-line Raw Mill: NoControl Device Configuration: Fabric Filter

Parameter

Sample #1

Sample #2

Sample #3

Test 

AverageUnits

Units 

Enter HCl cparts per mitest results aplease note (e.g., [< 0.01

ion value in dry 

me (ppmvd). If the 

 detection limit, 

tion limit in brackets 

Select appropriate unit from list. If other is selected please describe units in column H at right. 

Sample Date (mm/dd/yyyy) 3/25/2010 3/25/2010 3/25/2010

HCl Concentration - as measured - dry basis

34.84 33.79 29.55

ppmvd 

Oxygen Concentration - dry basis 6.22 5.96 6.18 % (dry)

CO2 Concentration - dry basis 23.35 23.63 23.24 % (dry)

HCl Concentration - corrected to 7% oxygen

32.99 31.43 27.91

ppmvd @ 7% O2 

Exhaust Stream %Moisture 5.87 5.56 5.25 %

Exhaust Flowrate 146090 144187 145502 SCFM

Exhaust Temperature ~ 400 ~ 400 ~ 400 degrees F

Sample Date (mm/dd/yyyy)

HCl Concentration - as measured - dry basis

N/A N/

d

A N/A

ppmvd 

Oxygen Concentration - dry basis N/A N/A N/A %

CO2 Concentration - dry basis N/A N/A N/A %
HCl Concentration N/A N/A N/A ppmvd @ 7% O2

Exhaust Stream %Moisture N/A N/A N/A %Exhaust Flowrate N/A N/A N/A (select flowrate units)

Exhaust Temperature N/A N/A N/A (select temperature units)Notes:Peach shaded cells indicate areas where the user will enter a response
Test Location Note

Indicate whether the test occurred upstream or downstream of a control device(s); list the control device(s)

If kiln has an in-line raw mill, indicate raw mill status during tests (i.e., raw mill on or raw mill off). Provide any other information supporting information you think is necessary about this test report. 

Downstream

NA

Based on preliminary Velocity Traverse on 3/24/2010

concentra

 volume (

. If the te

mit, pleas

ckets 

10]). 

00 0 79133

TABLE 1.2 EPA REPORTING SPREADSHEET

Company Name: Lone Star Industries Inc.Facility Name: PRYOR CEMENT PLANTAddress: 5 Mi E on 20 2 Mi S Co Rd City: PRYOR State: OklahomaKiln ID: Kiln Number 3Kiln Type: Long DryIn-line Raw Mill: NoControl Device Configuration: Baghouse

Parameter

ample #1 Samample #2 ample #3

Sa

m

Sam

Avg. Un

Enter HCl per million7% oxygendetection lilimit in bra(e.g., [< 0.0

tion value in dry pa

ppmvd) corrected to

st results are below 

e note the detection

Select appropfrom list. If oselected pleasunits in colum

rts 

Sample Date (mm/dd/yyyy) 2/24/2010 2/24/2010 2/24/2010HCl Concentration - as measured - Wet Basis 7.8 6.5 5.9 6.7 ppmv Wet 

HCl Concentration Dry Basis 8.2 6.8 6.2 7.1 ppm v Dry Oxygen Concentration - dry basis 12.1 12.7 12.4 12.4 % 

CO2 Concentration - dry basis 13.7 12.6 13.2 13.2 % 

HCl Concentration - dry corrected to 7% oxygen 13.0 11.5 10.1 11.5 ppm v dry at 

Exhaust Stream %Moisture 4.9 4.6 4.6 4.7 % 

E hxaust Flowrate Fl 77,800 82,4 77,20000 79133 dscf m 

Exhaust Temperature 372 370 389 377 F 
Notes:

Method 320 data used for moisture results reporting.
Test Location Note

Indicate whether the test occurred upstream or downstream of a control device(s); list the control device(s)

If kiln has an in-line raw mill, indicate raw mill status during tests (i.e., raw mill on or raw mill off). Provide any other information supporting information you think is necessary about this test report. 

Downstream of Baghouse Off Line Raw Mill Downstream of Baghouse Off Line Raw Mill Downstream of Baghouse Off Line Raw Mill Downstream of Baghouse Off Line Raw Mill Downstream of Baghouse Off Line Raw Mill Downstream of Baghouse Off Line Raw Mill 

D townsream of Baghous f B h e Off Line Raw Mill Li R MillDownstream of Baghouse Off Line Raw Mill 
ncentrat

me (ppm

t t ults are b l d li l f 

ction lim

0]). 

HCl Concentration dry corrected to 7% oxygen 96 9 108 0 95 5 100 1 ppm v dr

TABLE 1.2 EPA REPORTING SPREADSHEET

Company Name: California Portland Cement Co.

Facility Name: Mojave FacilityAddress: 9350 Oak Creek Rd Mojave CA 93501City: Mojave FacilityState: CaliforniaKiln ID: Kiln 1Kiln Type: Pre-Heater/ Pre-CalcinerIn-line Raw Mill: YesControl Device Configuration: Baghouse

Parameter

Sam

ple 

#1

Sam

ple 

#2

Sam

ple 

#3

Avg. 

EPA Instructions

Enter HCl comillion voluIf the es res t t

note the dete(e.g., [< 0.01

ion value in dry par

vd) corrected to 7%

be ow etect l d t tion mli

it in brackets 

Select ap

f li t 

ts per 

 oxygen. 

it l rom list

selected units in c

it, p ease 

Sample Date (mm/dd/yyyy) 3/30/2010 3/30/2010 3/30/2010

HCl Concentration - as measured - Wet Basis 6.3 6.3 5.8 6.1 ppmv W

HCl Concentration Dry Basis 6.9 6.9 6.3 6.7 ppm v DOxygen Concentration - dry basis 12.42 12.07 11.92 12.1 % 

CO2 Concentration - dry basis 19.1 19.1 19.1 19.1 % 

HCl Concentration - dry corrected to 7% oxygen 11.2 10.8 9.8 10.6 ppm v dr

Exhaust Stream %Moisture 8.2 8.2 8.2 8.2 % 

Exhaust Flowrate 259,488 259,249 253,513 257,417 dscfm 

Exhaust Temperature 219 230 230 226 F 

Sample Date (mm/dd/yyyy) 3/31/2010 3/31/2010 3/31/2010

HCl Concentration - as measured - Wet Basis 57.3 66.8 68.1 64.1 ppmv W

HCl Concentration Dry Basis 59.9 69.9 71.0 67.0 ppm v DOxygen Concentration - dry basis 12.3 11.9 10.56 11.6 % 

CO2 Concentration - dry basis 21.7 16.7 19.7 19.3 % 

HCl Concentration - dry corrected to 7% oxygen 96.9 108.0 95.5 100.1 ppm v drExhaust Stream %Moisture 4.4 4.5 4.1 4.3 % 

Exhaust Flowrate 218,776 200,306 214,974 211,352 dscfm 

Exhaust Temperature 354 411 410 392 F 
Notes:

Method 320 data used for moisture and CO2 results reporting.
f l i f

Downstream of Baghouse

Test Location Note

Indicate whether the test occurred upstream or 

d t ownsream o a contro f ldevice(s); list the control device(s)

If kiln has an in-line raw mill, indicate raw mill status during tests (i.e., raw mill on or raw mill off). Provide any 

other n ormat i fion supporting 

information you think is necessary about this test report. 

Downstream of Baghouse Raw Mill OnDownstream of BaghouseDownstream of BaghouseDownstream of BaghouseDownstream of BaghouseDownstream of BaghouseDownstream of BaghouseDownstream of BaghouseDownstream of Baghouse Raw Mill OffDownstream of BaghouseDownstream of BaghouseDownstream of Baghouse

Downstream of BaghouseDownstream of BaghouseDownstream of BaghouseDownstream of Baghouse
Method 321 Test Lonestar, Pryor, OK

August 6,2010

ter HCl 

 million

 oxygen

ection li

it in bra

., [< 0.0

TABLE 1.2 EPA REPORTING SPREADSHEET

Company Name: Lone Star Industries Inc.

Facility Name: PRYOR CEMENT PLANT

Address: 5 Mi E on 20 2 Mi S Co Rd 

City: PRYOR 

State: Oklahoma

Kiln ID: Kiln Number 3Kiln Type: Long DryIn-line Raw Mill: NoControl Device Configuration: Baghouse

Parameter

Sample #1

Sample #2

Sample #3

Avg. Units T

Enper7%detlim(e.g

concentration valu

 volume (ppmvd)

. If the test results

mit, please note th

ckets 

10]). 

e in dry parts 

 corrected to 

 are below 

e detection 

Select appropriatefrom list. If otherselected please deunits in column H

 unit 

 is 

scribe 

 at right. Enter the nam

Sample Date (mm/dd/yyyy) 2/24/2010 2/24/2010 2/24/2010HCl Concentration - as measured - Wet Basis 7.8 6.5 5.9 6.7 ppmv Wet M321 

HCl Concentration Dry Basis 8.2 6.8 6.2 7.1 ppm v Dry M321 Oxygen Concentration - dry basis 12.1 12.7 12.4 12.4 % M3A CO2 Concentration - dry basis 13.7 12.6 13.2 13.2 % M3A HCl Concentration - dry corrected to 7% oxygen 13.0 11.5 10.1 11.5 ppm v dry at 7% O2 M321 Exhaust Stream %Moisture 4.9 4.6 4.6 4.7 % M320 and M4 Exhaust Flowrate 77,800 82,400 77,200 79133 dscfm M1, 2, 3A and Exhaust Temperature 372 370 389 377 F T/C Notes:Method 320 data used for moisture results reporting.