EMISSION MEASUREMENT SUMMARY REPORT 

FILTERABLE PARTICULATE MATTER 

FURNACE 12 

FITLERABLE PARTICULATE MATTER, HCl/HF, AND MANGANESE 

FURNACE NO. 1 

ERAMET MARIETTA, INC. 

MARIETTA, OHIO 

Prepared for: 

Eramet Marietta, Inc. 

P.O. Box 299 

State Route 7 South 

Marietta, Ohio 45750-0299 

Prepared by: 

Environmental Quality Management, Inc. 

1800 Carillon Boulevard 

Cincinnati, Ohio 45240 

(513) 825-7500 

Fax (513) 825-7495 

www.eqm.com 

PN: 050352.0024 

June 2011
ii

CONTENTS

Section Page

1 Introduction...................................................................................................................... 1-1 

2 Summary of Test Results................................................................................................. 2-1 

3 Sampling and Analytical Procedures............................................................................... 3-1 

 3.1 Location of Measurement Sites ........................................................................... 3-1 

 3.2 Stack Gas Volumetric Flow Rate......................................................................... 3-1 

 3.3 Stack Gas Dry Molecular Weight........................................................................ 3-1 

 3.4 Stack Gas Moisture Content ................................................................................ 3-2 

 3.5 Filterable Particulate Matter ................................................................................ 3-2 

 3.6 Hydrogen Chloride and Hydrogen Fluoride ........................................................ 3-2 

 3.7 Manganese ........................................................................................................... 3-2 

 3.8 Visible Emissions................................................................................................. 3-3 

 

4 Process Description/Sampling Locations ........................................................................ 4-1 

5 Quality Assurance and Quality Control........................................................................... 5-1 

 5.1 Field Sampling..................................................................................................... 5-1 

 5.2 Calibration Procedures and Frequency ................................................................ 5-1 

Appendices: 

A Calculations 

B Raw Field Data 

C Analytical Data 

D Process and Visible Emission Observation Data 

E Quality Assurance/Quality Control 
iii

FIGURES 

Number Page

3-1 EPA Method 5/29 Sampling Train .................................................................................. 3-4 

3-2 EPA Method 26 Sampling Train...................................................................................... 3-5 

4-1 Sampling Locations ......................................................................................................... 4-2 

TABLES

Number Page

1-1 Sampling Locations and Test Parameters........................................................................ 1-2 

2-1 Furnace No. 12 Summary of Stack Conditions ............................................................... 2-3 

2-2 Furnace No. 12 Summary of Particulate Emissions and Process Operations.................. 2-3 

2-3 Furnace No. 1 Summary of Stack Conditions ................................................................. 2-4 

2-4 Furnace No. 1 Summary of PM and Manganese Emissions and Process Operations ..... 2-5 

2-5 Furnace No. 1 Summary of HCl and HF Emissions ....................................................... 2-6 

4-1 Sampling Location Parameters ........................................................................................ 4-2 

5-1 Field Equipment Calibrations .......................................................................................... 5-2 

5-2 Field Checks of Sampling Equipment ............................................................................. 5-2 
1-1 

SECTION 1 

INTRODUCTION 

On May 25 and 26, 2011, Environmental Quality Management, Inc. (EQ) personnel 

conducted a compliance air emission program at the Eramet Marietta Inc. (Eramet) facility in 

Marietta, Ohio. Sampling was conducted following the procedures of EPA Reference Methods 1 

through 5, and 9 to quantify emissions of filterable particulate matter from Furnace No. 12. 

Sampling was conducted following the procedures of EPA Reference Methods 1 through 5, 9, 

26, and 29 to quantify emissions of filterable particulate matter, hydrogen chloride, hydrogen 

fluoride acid, and manganese from Furnace No. 1. 

EQ utilized EPA Reference Methods 1 and 2 to calculate stack gas velocities and 

temperatures. EPA Method 3 was used to determine the stack gas molecular weight. Moisture, 

filterable particulate matter, and visible emissions were measured following the procedures of 

EPA Methods 4, 5, and 9, respectively. Hydrogen chloride and hydrogen fluoride were measured 

following the procedures of EPA Method 26. Manganese emissions were obtained using EPA 

Method 29. An outline of the specific sampling methods and parameters utilized is provided in 

Table 1-1 and detailed in Section 3. 

Mr. John Hughes of Eramet monitored process operations during testing. Ms. Christina 

Wieg, Ms. Lisa Duvall, and Mr. Marco Deshaies of the Ohio Environmental Protection Agency 

(Ohio EPA) observed process operations and sampling efforts. Mr. John Rowe of EQ managed 

the sampling effort. Messrs. Dan Scheffel, Tom Gerstle, Doug Allen, Mike Todd, Gary Drexler, 

Chris Janzen, and Richard Kelly of EQ conducted the emission testing. 
1-2 

TABLE 1-1. SAMPLING LOCATIONS AND TEST PARAMETERS 

Stack I.D. Test 

Method 

Parameter No. of 

Samples

Run Time/Sample, 

min 

Furnace No.12 

Scrubber 

Exhaust 

May 25, 2011 

1-2 

3 

4 

5 

9 

Flow 

CO2/O2

Moisture 

Filterable PM 

Opacity 

3 

3 

3 

3 

1 

60 

60 

60 

60 

60 

Furnace No.1 

Main and Taphole 

Baghouse Exhausts 

May 26, 2011 

1-2 

3 

4 

5 

9 

26 

29 

Flow 

CO2/O2

Moisture 

Filterable PM 

Opacity 

HCl/HF 

Manganese 

3 

3 

3 

3 

1 

3 

3 

120 

120 

120 

120 

60 

120 

120 
2-1 

SECTION 2 

SUMMARY OF TEST RESULTS 

Furnace No. 12 (scrubber exhaust) was sampled on May 25, 2011 to quantify emissions 

of filterable particulate. Furnace No. 12 was sampled at a maximum furnace load, approximately 

19.54 MW. Three 1-hour test runs were conducted at the Furnace No. 12 scrubber exhaust to 

determine the concentration and mass emission rate of filterable particulate matter. Sampling 

was conducted following EPA Reference Methods 1 through 5. 

Furnace No. 1 (2 baghouse exhausts) was sampled on May 26, 2011 to quantify 

emissions of filterable particulate, manganese, hydrogen chloride, and hydrogen fluoride. The 

main baghouse controls emissions from the furnace and the taphole baghouse controls emissions 

from the tapping operations. The furnace was sampled at a maximum furnace load, 

approximately 27.12 MW. Three 2-hour test runs were conducted at each baghouse. Sampling 

was conducted following EPA Reference Methods 1 through 5, 26, and 29. 

EPA Reference 9, “Visible Determination of the Opacity of Emissions from Stationary 

Sources,” was used to determine opacity from the furnace roof monitor for Furnace Nos. 1 and 

12. A 1-hour emission observation was completed in conjunction with the particulate sampling 

runs. The opacity averaged 3.4% for the Furnace No. 1 roof monitor with occasional 5% to 20% 

opacity observed during tapping. The opacity averaged 1.7% for the Furnace No. 12 roof 

monitor with occasional 5% to 20% opacity observed during tapping. 

Table 2-1 summarizes the stack gas conditions measured during each sampling run for 

Furnace No. 12. Stack gas velocity and temperature, volumetric flow rates, gas composition 

(CO2 and O2), and moisture content are detailed for each test run. 

Table 2-2 summarizes the filterable particulate matter and pertinent production data for 

each test run for Furnace No. 12. In addition, a tap was conducted during all three test runs. 

Table 2-3 summarizes the stack gas conditions measured during each sampling run for 

Furnace No. 1. Stack gas velocity and temperature, volumetric flow rates, gas composition (CO2

and O2), and moisture content are detailed for each test run. 
2-2 

Table 2-4 summarizes the filterable particulate matter, manganese emissions, and 

pertinent production data for each test run for Furnace No. 1. In addition, a tap was conducted 

during all three test runs. 

Table 2-5 summarizes the hydrogen chloride (HCl) and hydrogen fluoride (HF) 

concentrations and emissions for each test run for Furnace No. 1. 

Example calculations are included as Appendix A, raw field data is included as Appendix 

B, analytical data is included in Appendix C, process and visible emissions observation data are 

included in Appendix D, and quality assurance/quality control data are located in Appendix E. 
TABLE 2-1. FURNACE NO. 12 

SUMMARY OF STACK GAS CONDITIONS

Dates: May 25, 2011 Plant: Era

Volumetric Flow Rate 

Run No. Time 

Stack Gas 

Velocity, 

fpsa acfmb dscfmc Temp, °F Moisture, % CO2, 

12-1 0754-0856 54.5 162,036 133,190 132 6.1 2.0 12-2 0951-1100 54.7 162,797 134,572 132 5.6 1.5 12-3 1135-1239 54.7 162,869 134,356 132 5.7 1.0 

Average 54.6 162,567 134,040 132 5.8 1.5 

aFeet per second. bActual cubic feet per minute. cDry standard cubic feet per minute. 

TABLE 2-2. FURNACE NO. 12 

SUMMARY OF PARTICULATE EMISSIONS AND PROCESS OPERATIONS 

Date: May 25, 2011 Plant: Eram

Filterable Particulate Matter 

Run No. Time Concentration 

gr/dscfa lb/dscfb

Mass Rate, 

lb/hrc

Process Throughput 

Tons/hr at furnace load 

(MW) 

Pin

12-1 0754-0856 6.03E-03 8.61E-07 6.88 18.98 at 20.20 MW 51.8 12-2 0951-1100 5.80E-03 8.29E-07 6.69 18.98 at 19.49 MW 52.4 12-3 1135-1239 4.10E-03 5.86E-07 4.72 18.98 at 18.93 MW 52.

Average 5.31E-03 7.59E-07 6.10 18.98 at 19.54 MW 52.2 

aGrains per dry standard cubic foot. bPounds per dry standard cubic foot. cPounds per hour. 

2-3
TABLE 2-3. FURNACE NO. 1 

 SUMMARY OF STACK GAS CONDITIONS

Dates: May 26, 2011 Plant: Era

Volumetric Flow Rate 

Run No. Time 

Stack Gas 

Velocity, 

fpsa acfmb dscfmc Temp, °F Moisture, % CO2, 

Furnace No. 1 Main Baghouse 

29-MA-1 0734-1008 52.3 246,462 189,240 209 2.3 0.0 29-MA-2 1030-1237 51.6 243,330 181,874 228 2.2 0.0 29-MA-3 1310-1516 52.2 246,074 184,727 225 2.2 00 

Average 52.1 245,289 185,280 221 2.2 0.0 

Furnace No. 1 Taphole Baghouse

29-ME-1 0734-0944 37.8 48,182 43,666 112 1.6 0.0 29-ME-2 1030-1241 37.4 47,710 42,887 117 1.7 0.0 29-ME-3 1310-1517 36.7 46,791 41,608 122 1.8 0.0 

Average 37.3 47,561 42,720 117 1.7 0.0 

aFeet per second. bActual cubic feet per minute. cDry standard cubic feet per minute. 

2-4
TABLE 2-4. FURNACE NO. 1 

SUMMARY OF PM AND MANGANESE EMISSIONS AND PROCESS OPERATION

Date: May 26, 2011 Plant: Eram

Filterable Particulate Matter 

Concentration 

Run No. Time 

gr/dscfa lb/dscfb

Mass Rate, 

lb/hrc

Manganese 

Mass Rate, 

lb/hrc 

Process 

Throughput 

Tons/hr at 

furnace load 

(MW) 

Furnace No. 1 Main Baghouse

29-MA-1 0734-1008 1.64E-03 2.34E-07 2.66 0.212 33 at 26.50 29-MA-2 1030-1237 3.89E-04 5.56E-08 0.61 0.186 33 at 27.54 29-MA-3 1310-1516 2.90E-04 4.15E-08 0.46 0.179 33 at 27.31 

Average 7.73E-04 1.10E-07 1.24 0.192 33 at 27.12 

Furnace No. 1 Taphole Baghouse

29-ME-1 0734-0944 1.03E-03 1.48E-07 0.39 0.053 33 at 26.50 29-ME-2 1030-1241 8.50E-04 1.21E-07 0.31 0.043 33 at 27.54 29-ME-3 1310-1517 1.65E-03 2.36E-07 0.59 0.074 33 at 27.31 

Average 1.18E-03 1.68E-07 0.43 0.057 33 at 27.12 

aGrains per dry standard cubic foot. bPounds per dry standard cubic foot. cPounds per hour. 

2-5
TABLE 2-5. FURNACE NO. 1 

SUMMARY OF HCL AND HF EMISSIONS 

Date: May 26, 2011 Plant: Eram

HCl HF 

Run No. Time Concentration, 

ppmdva

Mass Rate, 

lb/hrb

Concentration, 

ppmdva

Furnace No. 1 Main Baghouse

26-MA-1 0734-0934 2.91E-04 3.13E-04 1.26E-03 26-MA-2 1103-1303 2.89E-04 2.99E-04 1.30E-03 26-MA-3 1315-1523 2.66E-04 2.80E-04 1.22E-03 

Average 2.82E-04 2.97E-04 1.26E-03 

Furnace No. 1 Taphole Baghouse

26-ME-1 0734-0934 3.57E-04 8.82E-05 1.60E-03 26-ME-2 1030-1230 3.02E-04 8.03E-05 1.35E-03 26-ME-3 1310-1510 2.48E-04 5.86E-05 1.15E-03 

Average 3.02E-04 7.57E-05 1.37E-03 

aParts per million, dry basis bPounds per hour. 

2-6
3-1 

SECTION 3 

SAMPLING AND ANALYTICAL PROCEDURES

The sampling and analytical procedures used in this test program conformed to EPA 

Reference Methods 1 through 5, 9, 26, and 29 as published in the Federal Register. 

3.1 Location of Measurement Sites

EPA Method 1, “Sample Velocity Traverses for Stationary Sources,” was used to select 

representative measurement sites. Sample locations are discussed in Section 4. Exact 

measurements were verified on site. 

3.2 Stack Gas Volumetric Flow Rate

 EPA Method 2, “Determination of Stack Gas Velocity and Volumetric Flow Rates,” was 

used at each location to determine stack gas volumetric flow rates. Standard and Type “S” pitot 

tubes meeting EPA specifications and an inclined manometer were used to measure velocity 

pressures. A calibrated Type “K” thermocouple attached directly to the pitot tube was used to 

measure stack gas temperature. The stack gas velocity was calculated from the average square 

root of the stack gas velocity pressure, average stack gas temperature, stack gas molecular 

weight, and absolute static pressure. The volumetric flow rate is the product of velocity and 

stack cross-sectional area. 

3.3 Stack Gas Dry Molecular Weight

EPA Method 3, “Gas Analysis for the Determination of Dry Molecular Weight,” was 

used to determine the stack gas dry molecular weight at all sampling locations. Fyrite analyzer 

readings were conducted for oxygen and carbon dioxide. 
3-2 

3.4 Stack Gas Moisture Content 

EPA Method 4, “Determination of Moisture Content in Stack Gases,” was used to 

determine stack gas moisture content. This method was conducted as part of each particulate 

measurement run. The initial and final contents of all impingers were determined 

gravimetrically. 

3.5 Filterable Particulate Matter 

 EPA Method 5, “Determination of Particulate Emissions from Stationary Sources,” was 

used to determine filterable particulate matter. The sampling train consisted of a nozzle, glasslined probe, heated quartz-fiber filter, and a series of impingers filled with appropriate reagents, 

followed by a vacuum pump, dry gas meter, and calibrated orifice. The probe and filter 

temperatures were maintained at 248o

 ± 25o F. Thermocouples were used to monitor 

temperatures of the stack gas, sample probe, filter, and impinger exit gas. Three 1-hour sampling 

runs were conducted at Furnace No. 12, and three 2-hour sampling runs were conducted at the 

Furnace No. 1 main and taphole baghouse exhausts. Figure 3-1 is a schematic of the sampling 

system. 

3.6 HCl and HF 

Hydrogen chloride (HCl) and hydrogen fluoride (HF) emissions were measured at the 

Furnace No. 1 main and taphole baghouse exhausts following the procedures of EPA Method 26. 

The sampling reagent consisted of 0.1 Normal sulfuric acid in the first two impingers followed 

by two impingers containing 0.1 Normal sodium hydroxide. The individual portions were 

recovered with a deionized water rinse and analyzed by ion chromatography. Figure 3-2 is a 

schematic of the sampling system. Three 2-hour test runs were completed. 

3.7 Manganese 

EPA Method 29, “Determination of Multiple Metals Emissions from Stationary Sources,” 

was used to determine manganese emissions. Sampling was conducted using a Method 5 

sampling train with appropriate reagents in the back half for metals collection. Analysis was 

conducted by Inductively Coupled Argon Plasma Spectrometry (ICAP). Figure 3-1 is a 
3-3 

schematic of the sampling train. Three 2-hour test runs were completed at the Furnace No. 1 

main and taphole baghouse exhausts in conjunction with the particulate sampling. 

3.8 Visible Emissions 

 EPA Method 9, “Visual Determination of the Opacity of Emissions from Stationary 

Sources,” was used to measure visible emissions from the building roof monitor. One 60-minute 

test run was conducted at each test site. Opacity readings were recorded every 15 seconds by a 

certified observer. 
3-4 

Figure 3-1. EPA Method 5/29 Sampling Train 
3-5 

Figure 3-2. EPA Method 26 Sampling Train
4-1 

SECTION 4 

PROCESS DESCRIPTION/SAMPLING LOCATIONS

Eramet Marietta, Inc., operates a facility in Marietta, Ohio. The No. 12 Furnace and No. 

1 Furnace were tested at the facility as part of this test program. The No. 12 Furnace, a 

submerged arc furnace, is rated at 22 MW and utilizes two wet scrubbers to control primary and 

secondary emissions. The scrubbers operate simultaneously and exhaust through a single stack. 

The No. 1 Furnace, a manganese electric arc furnace, is rated at 30MW and a maximum 

production rate of 35 tons per hour. A baghouse controls emissions from the furnace tap hole, 

and a new baghouse, which replaced an existing scrubber, controls emissions from the furnace. 

 Table 4-1 presents a summary of the sampling site location. Figure 4-1 is a general 

schematic of the testing locations. 
4-2 

B

A

C

Direction of

Flow

Figure 4-1. Sampling Locations 

TABLE 4-1. SAMPLING LOCATION PARAMETERS 

Distance from Nearest 

Disturbance 

Stack 

Identification 

Stack I.D., 

Inches 

(C) 

Upstream, 

Inches 

(A) 

Downstream, 

Inches 

(B) 

No. of Sampling 

Points Required, 

Total 

Furnace No. 12 

Scrubber 95.35” >194.0 368.0 24 

Furnace No. 1 

Main Baghouse 120” 480.0” 480.0” 24 

Furnace No. 1 

Taphole Baghouse 60”x51” >190.0 95.0 24 
5-1 

SECTION 5 

QUALITY ASSURANCE AND QUALITY CONTROL 

5.1 Field Sampling

The field sampling quality assurance for this project included the use of calibrated source 

sampling equipment, reference test methods, and traceability protocols for recording and 

calculating data. The analytical quality assurance included use of validated analytical 

procedures, calibration of analytical instruments, and analysis of control samples and blanks. 

The calibration and quality control procedures used for this test program are described in the 

following subsection, and included in Appendix E of this report. 

5.2 Calibration Procedures and Frequency

All manual stack gas sampling equipment was calibrated before the test program in 

accordance with the procedures outlined in the Quality Assurance Handbook for Air Pollution 

Measurement Systems, Volume III, EPA-600/4-72-027B. Summarized in Table 5-1 are the stack 

gas sampling equipment calibrations that were performed in preparation for this project. The 

meter boxes were re-calibrated after the test. 

Listed in Table 5-2 are the additional calibration checks that were performed on the 

sampling equipment on site, just prior to the testing, to ensure that equipment was not damaged 

during transport. Calibration checks were conducted before and after each test run. Additional 

calibration information is included in Appendix E of this report. 
5-2 

TABLE 5-1. FIELD EQUIPMENT CALIBRATIONSa

Equipment Calibrated Against Allowable Error 

Method 5 meter box Reference test meter 

Y +0.02 Y 

ΔH@ +0.20 ΔH@ 

post-test 

Y +0.05 Y 

Pitot tube Geometric specifications See EPA Method 2 

Thermocouple ASTM-3F thermometer +1.5% 

Impinger (or condenser 

thermometer) ASTM-3F +2oF 

Dry gas meter 

thermometer ASTM-3F +5o

F 

Probe nozzles Caliper High-low +0.004 in. 

Barometer NBS traceable barometer +0.1 in.Hg 

a

As recommended in the Quality Assurance Handbook for Air Pollution Measurement 

Systems: Volume III. Stationary Source-Specific Methods. EPA-600/4-77-027b, August 

1977.

TABLE 5-2. FIELD CHECKS OF SAMPLING EQUIPMENT

Equipment Checked Against Allowable Difference 

Pitot tube Inspection No visible damage 

Thermocouples ASTM 2F or 3F +1.5% 

Probe nozzles Caliper High-low ±0.004 in.