## EMISSION MEASUREMENT SUMMARY REPORT

FILTERABLE PARTICULATE MATTER

FURNACES 1 and 12

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

(800) 229 -7495

www.eqm.com

EQ PN: 050352.0030

April 20 14ii CONTE NTS

Section Page

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

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

3. Sampling and Analytical Procedures ............................................................................... 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 Visible Emission Observations ............................................................................... 3 -2

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

Appendix A Calculations

Appendix B Raw Field Data

Appendix C Analytical Data

Appendix D Process Data and Visible Emission Observation Data

Appendix E Quality Assurance/Quality Controliii F IGURES

No. Page

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

Figure 4-1. Sampling Locations ................................................................................................ 4-1

TABLES

No. Page

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

Table 2-1. Furnace No. 12 Stack Gas Conditions .................................................................... 2 -2

Table 2-2. Furnace No. 12 Particulate Emissions and Process Operations .............................. 2-2

Table 2-3. Furnace No. 1 Stack Gas Conditions ...................................................................... 2 -3

Table 2-4. Furnace No. 1 PM Emissions and Process Operations ........................................... 2 -4

Table 2-5. Furnace No.1 Baghouse Pressure Drop .................................................................. 2 -4

Table 4-1. Sampling location parameters ................................................................................. 4 -1

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

Table 5-2. Fi eld Checks of Sampling Equipment .................................................................... 5 -21 -1 1. INTRODUCTION

On March 25 th and 26 th 2014 , 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 to quantify emissions of filterable particulate matter from Furnace No. 12. Sampling

wa s conducted following the procedures of EPA Reference Methods 1 through 5to quantify

emissions of filterable particulate matter from Furnace No. 1.

EQ u tilized 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

and filterable particulate matter were measured following the procedures of EPA Methods 4 and

5 respectively. 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. Lisa

Duvall of the Ohio Environmental Protection Agency (Ohio EPA) observed process operations

and sampling efforts. Mr. Tom Gerstle of EQ managed the sampling effort. Messrs. Dan

S cheffel, Doug Allen, Benjamin Fern, Gary Drexle r, Chris Janzen, Andrew Kriegbaum, Karl

Masta lski, TJ Wigmore, and Jeffery Cavanaugh of EQ conducted the emission testing.

T able 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

March 25, 2014 1

- 2

3

4

5

9 Flow

CO 2 /O 2

Moistu re

Filterable PM

Opacity 3

3

3

3

1 60

60

60

60

60

Furnace No.1

Main Baghouse and

Taphole Baghouse

Exhaust

March 25

- 26, 2014 1

- 2

3

4

5

9 Flow

CO 2 /O 2

Moisture

Filterable PM

Opacity 3

3

3

3

1 60

60

60

60

602 -1 2. SUMMARY OF TEST RESU LTS

Furnace No. 12 (scrubber exhaust) was sampled on March 25, 2014 to quantify emissions

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

19.58 MW

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

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

was conducted following EPA Reference Methods 1 through 5.

F urnace No. 1 (2 baghouse exhausts) was sampled on March 25- 26, 2014 to quantify

e missions of filterable particulate. The main baghouse controls emissions from the furnace and

th e taphole baghouse controls emissions from the tapping operations. The furnace was sampled

a t a maximum furnace load, approximately 25.49 MW

. Three 1 -hour test runs were conducted at

each baghouse. Test Runs 1 and 2 were completed during a Tap. Sampling was conducted

following EPA Reference Methods 1 through 5.

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

(CO 2 and O 2 ), and moisture content are detailed for each test run.

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

e ach 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 three test runs for

F urnace No. 1. Stack gas velocity and temperature, volumetric flow rates, gas composition (CO 2

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

Table 2-4 summarizes the filterable particulate matter and pertinent production data for

e ach test run for Furnace No. 1. In addition, a tap was conducted during all three test runs.

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.2-2 Table 2 -1

. Furnace No. 12 Stack Gas Conditions

March 25, 2014 E ramet, Marietta, Ohio

Run No. Time Stack Gas

Velocity,

fps a Volumetric Flow Rate

Temp,  F Moisture,

% CO 2 , % O 2 , % acfm b dscfm c

12

- 1 0757

- 0 900 5 9.3 176,325 158,075 11 2 3.2 0.0 20.5

12

- 2 0923

- 1 026 61.2 182,015 1 62,619 1 14 3.7 0.0 20. 5

12

- 3 1050

- 1 153 60.0 178,469 1 58,290 1 16 4.1 0.0 20. 5

Average 60.1 1 78,936 1 59,661 1 14 3.7 0.0 20. 5

a Feet per second.

b Actual cubic feet per minute.

c Dry standard cubic feet per minute.

Table 2 -2 . Furnace No. 12 Particulate Emissions and Process Operations

March 25, 201 4 Eramet, Marietta, Ohio

Run No. Time Filterable Particulate Matter

Process Throughput Tons/hr

at furnace load (MW) Pressure Drop,

inches of water Concentration

grdscf a Mass Rate

lb/hr b

12

- 1 0757

- 0900 6. 78 E

- 03 9.2 23.56 at 19.09 MW 55.6 east 55.7 west

12

- 2 0923

- 1026 8.21E

- 03 11.4 23.56 at 20.05 MW 55.5 east 55.5 west

12

- 3 1050

- 1153 9.48E

- 03 12.9 23.56 a t 19.61 MW 55.2 east 55.3 west

Average 8.15E

- 03 11.2 23.56 at 19.58 MW 55.4 e ast 55.5 west

a Grains per dry standard cubic foot.

b Pounds per hour.2-3 Table 2 -3

. Furnace No. 1 Stack Gas Conditions

March 25-26, 2014 Eramet, Marietta, Ohio

Run No. Time Stack Gas

Velocity,

fps a Volumetric Flow Rate

Temp,  F Moisture,

% CO 2 , % O 2 , % acfm b dscfm c

Furnace No. 1 Main Baghouse

MB

- 1 1411

- 1517 52. 8 248,628 223,043 126 0.7 0.0 20.5

MB

- 2 0750

- 0856 51. 7 243, 697 220,118 124 1.0 0.0 2 0.5

MB

- 3 0910

- 1017 50 .2 236,509 205,889 135 2.8 00 2 0.5

Average 5 1.6 242,944 216,350 128 1.5 0.0 2 0. 5

Furnace No. 1 Tap H ole Baghouse

TB

- 1 1411

- 1517 46.4 59,112 57,861 62 0.9 0.0 21.0

TB

- 2 0750

- 0856 42.9 54,643 56,507 51 0.3 0.0 20.5

TB

- 3 0910

- 1017 44.2 56,381 58,330 47 1.2 0.0 20.5

Average 44.5 56,712 57,566 53 0.8 0.0 20.7

a Feet per second.

b Actual cubic feet per minute.

c Dry standard cubic feet per minute.2-4 Table 2-4. Furnace No . 1 PM Emissions and Process Operations

Ma rch 25-26 , 201 4 Eramet, Marietta, Ohio

Run No. Time Filterable Particulate Matter

Process Throughput

Tons/hr at furnace load

( MW) Concentration Mass Rate

gr/dscf

a lb/hr b

Furnace No. 1 Main Baghouse

MB

- 1 1411

- 1517 2.13E

- 03 4.08 30.19 at 22.76MW

MB

- 2 0750

- 0856 8.90E

- 04 1.68 32.81 at 26.47MW

MB

- 3 0910

- 1017 1.88E

- 03 3.31 32.81 at 27.24MW

Average 1.63E

- 03 3.02 31.94 at 2 5.49MW

Furnace No. 1 Taphole Baghouse

TB

- 1 1411

- 1517 6.65E

- 03 3.30 30.19 at 22.76MW

TB

- 2 0750

- 0856 1.07E

- 02 5.16 32.81 at 26.47MW

TB

- 3 0910

- 1017 4.01E

- 03 2.01 32.81 at 27.24MW

Average 7.11E

- 03 3.49 31.94 at 25.49MW

Furnace No. 1 Total

1 8.78E

- 03 7.4

2 1.16E

- 02 6.8

3 5.89E

- 03 5.3

Average 8.76E

- 03 6.5

a Grains per dry standard cubic foot.

b Pounds per hour.

Table 2 -5

. Furnace No.1 Baghouse Pressure Drop

March 25-26, 2014 Eramet, Marietta, OH

Pressure Drop, Inches of Water

Run Time Mod 1 M od 2 Mod 3 Mod 4 Mod 5 Mod 6 Mod 7 Mod 8

1410

- 1521 6.59 6.45 6.21 11.36 6.00 6.42 6.01 11.02

0 750

- 0 857 7.26 6.52 6.92 11.33 6.83 6.66 6.90 11.48

0 910

- 1017 6.89 7.13 6.59 11.80 6.89 7.01 7.03 11.50

Average 6.91 6.70 6.57 11.49 6.57 6.70 6.65 11.333 -1 3. SAMPLING AND ANALYTICAL PROCEDURES

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

Reference Methods 1 through 5 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

re presentative 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 mee ting 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

mea sure 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

de termine 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, glassli ned 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 248 o ± 25 o 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 1-hour sampling runs were conducted at the

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

s ystem.

3.6 Visible Emission Observations

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

Sources,” was used to determine the opacity from each source during the test program. Each

sourc e was observed for 60 minutes.3 -3 Figure 3-1. EPA Method 5 Sampling Train4 -1 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

sc hematic of the testing locations.

Figure 4-1. Sampling Locations

Table 4-1. Sampling location parameters

Stack Identification Stack ID, i nches

(C) Distance from Nearest Disturbance No. of Sampling

Points

Required,

Total Upst ream, i nches

(A) Downstream, i nches

(B)

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 95.0 245 -1 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 Calibrations a

Equipment Calibrated Against Allowable Error

Method 5 meter box Reference test meter Y + 0.02 Y

 H@ + 0.20  H@

post

- test

Y + 0.05 Y

Pitot tube Geometric specifi cati ons See EPA Method 2

Thermocouple ASTM

- 3F thermometer + 1.5%

Impinger (or condenser

thermometer) ASTM

- 3F + 2 o F

Dry gas meter

thermometer ASTM

- 3F + 5 o F

Probe nozzles Caliper High

- low + 0.004 in.

Barometer NBS traceable barome ter + 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

P itot tube Inspection No visible damage

Thermocouples ASTM 2F or 3F + 1.5%

Probe nozzles Caliper High

- low  0.004 in.APPENDIX A

CALCULATIONSAPPENDIX B

RAW FIELD DATAAPPENDIX C

ANALYTICAL DATAAPPENDIX D

PROCESS DATA AND VISIBLE EMISSION OBSERVATION DATAAPPENDIX E

QUALITY ASSURANCE/QUALITY CONTROL